Systems and methods of controlling a clamping member firing rate of a surgical instrument

ABSTRACT

Various systems and methods of controlling a surgical instrument are disclosed. The surgical instrument can include a motor and a control circuit coupled to the motor. The motor can be coupled to a clamping member, which is configured to transition an end effector between an open position and a closed position, cut tissue, and/or eject staples from a staple cartridge in the end effector. The control circuit can be programmed to cause the motor to drive a clamping member at a first rate in a first zone between the first position and the second position and cause the motor to drive the clamping member at a second rate in a second zone between the first position and the second position; wherein the first rate is less than the second rate.

BACKGROUND

The present invention relates to surgical instruments and, in various arrangements, to surgical stapling and cutting instruments and staple cartridges for use therewith that are designed to staple and cut tissue.

While several devices have been made and used, it is believed that no one prior to the inventors has made or used the device described in the appended claims.

SUMMARY

In one aspect, a surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position and a second position, wherein the clamping member is configured to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge after the end effector is in the closed position as the clamping member moves to the second position; wherein the control circuit is further configured to: cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position; and cause the motor to drive the clamping member at a second rate in a second zone between the first position and the second position; wherein the first rate is less than the second rate.

In another aspect, a surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position, a second position, and a third position, wherein the clamping member is configured to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position; wherein the control circuit is further configured to: cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position; and cause the motor to drive the clamping member at a second rate in a second zone between the second position and the third position; wherein the first rate is less than the second rate.

In another aspect, a surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position, a second position, and a third position, wherein the clamping member is configured to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position; wherein the control circuit is further configured to cause the motor to drive the clamping member at a variable rate corresponding to a location of the clamping member between the second position and the third position, the variable rate being slower nearer to the second position.

FIGURES

Various features of the embodiments described herein, together with advantages thereof, may be understood in accordance with the following description taken in conjunction with the accompanying drawings as follows:

FIG. 1 is a perspective view of an electromechanical surgical system;

FIG. 2 is a perspective view of a distal end of an electromechanical surgical instrument portion of the surgical system of FIG. 1;

FIG. 3 is an exploded assembly view of an outer shell feature and the electromechanical surgical instrument of FIG. 2;

FIG. 4 is a rear perspective view of a portion of the electromechanical surgical instrument of FIG. 2;

FIG. 5 is a partial exploded assembly view of a portion of an adapter and the electromechanical surgical instrument of the surgical system of FIG. 1;

FIG. 6 is an exploded assembly view of a portion of the adapter of FIG. 5;

FIG. 7 is a cross-sectional perspective view of a portion of an articulation assembly of an adapter;

FIG. 8 is a perspective view of the articulation assembly of FIG. 7;

FIG. 9 is another perspective view of the articulation assembly of FIG. 8;

FIG. 10 is an exploded assembly view of a loading unit employed in the electromechanical surgical system of FIG. 1;

FIG. 11 is a perspective view of an alternative adapter embodiment;

FIG. 12 is a side elevational view of a portion of a loading unit of the adapter of FIG. 11 with the jaws thereof in an open position;

FIG. 13 is another side elevational view of a portion of the loading unit of FIG. 11 with portions thereof shown in cross-section and the jaws thereof in a closed position;

FIG. 14 is a bottom view of a portion of the loading unit of FIG. 13 with portions thereof shown in cross-section;

FIG. 15 is a perspective view of a portion of the loading unit of FIG. 11 with a portion of the outer tube shown in phantom lines;

FIG. 16 is a schematic diagram of a circuit for controlling a motor of a surgical instrument;

FIG. 17 is a schematic diagram of a circuit for controlling a motor of a surgical instrument;

FIG. 18 is a schematic diagram of a position sensor of a surgical instrument;

FIG. 19 is a logic flow diagram of a process for monitoring a motor current of a surgical instrument;

FIG. 20 is a pair of graphs of various clamping member strokes executed per the logic depicted in FIG. 19;

FIG. 21 is a pair of graphs of various clamping member strokes executed per the logic depicted in FIG. 19;

FIG. 22 is a diagram of an end effector including a gap sensor and a cartridge identity sensor;

FIG. 23 is a schematic diagram of a Hall effect sensor;

FIG. 24 is a cutaway view of the end effector partially joined to the distal end of the adapter;

FIG. 25 is a sectional of the end effector joined to the distal end of the adapter along the longitudinal axis thereof;

FIG. 26 is a logic flow diagram of a process for selecting an initial speed at which to fire the clamping member; and

FIG. 27 is a graph of various clamping member strokes executed per the logic illustrated in FIG. 26.

DESCRIPTION

Applicant of the present application owns the following U.S. Patent Applications that were filed on Dec. 15, 2017 and which are each herein incorporated by reference in their respective entireties:

U.S. patent application Ser. No. 15/843,485, entitled SEALED ADAPTERS FOR USE WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Pat. No. 10,743,874;

U.S. patent application Ser. No. 15/843,518, entitled END EFFECTORS WITH POSITIVE JAW OPENING FEATURES FOR USE WITH ADAPTERS FOR ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2019/0183496;

U.S. patent application Ser. No. 15/843,535, entitled SURGICAL END EFFECTORS WITH CLAMPING ASSEMBLIES CONFIGURED TO INCREASE JAW APERTURE RANGES, now U.S. Patent Application Publication No. 2019/0183498;

U.S. patent application Ser. No. 15/843,558, entitled SURGICAL END EFFECTORS WITH PIVOTAL JAWS CONFIGURED TO TOUCH AT THEIR RESPECTIVE DISTAL ENDS WHEN FULLY CLOSED, now U.S. Patent Application Publication No. 2019/0183499;

U.S. patent application Ser. No. 15/843,528, entitled SURGICAL END EFFECTORS WITH JAW STIFFENER ARRANGEMENTS CONFIGURED TO PERMIT MONITORING OF FIRING MEMBER, now U.S. Pat. No. 10,743,875;

U.S. patent application Ser. No. 15/843,567, entitled ADAPTERS WITH END EFFECTOR POSITION SENSING AND CONTROL ARRANGEMENTS FOR USE IN CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Pat. No. 10,779,825;

U.S. patent application Ser. No. 15/843,556, entitled DYNAMIC CLAMPING ASSEMBLIES WITH IMPROVED WEAR CHARACTERISTICS FOR USE IN CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Patent Application Publication No. 2019/0183490;

U.S. patent application Ser. No. 15/843,514, entitled ADAPTERS WITH FIRING STROKE SENSING ARRANGEMENTS FOR USE IN CONNECTION WITH ELECTROMECHANICAL SURGICAL INSTRUMENTS, now U.S. Pat. No. 10,687,813;

U.S. patent application Ser. No. 15/843,501, entitled ADAPTERS WITH CONTROL SYSTEMS FOR CONTROLLING MULTIPLE MOTORS OF AN ELECTRICAL MECHANICAL SURGICAL INSTRUMENT, now U.S. Pat. No. 10,869,666;

U.S. patent application Ser. No. 15/843,508, entitled HANDHELD ELECTROMECHANICAL SURGICAL INSTRUMENTS WITH IMPROVED MOTOR CONTROL ARRANGEMENTS FOR POSITIONING COMPONENTS OF AN ADAPTER COUPLED THERETO, now U.S. Pat. No. 10,828,033;

U.S. patent application Ser. No. 15/843,689, entitled SYSTEMS AND METHODS OF CONTROLLING A CLAMPING MEMBER, now U.S. Patent Application Publication No. 2019/0183502; and

U.S. patent application Ser. No. 15/843,704, entitled METHODS OF OPERATING SURGICAL END EFFECTORS, now U.S. Pat. No. 10,779,826.

Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. Well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. The reader will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and illustrative. Variations and changes thereto may be made without departing from the scope of the claims.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), “include” (and any form of include, such as “includes” and “including”) and “contain” (and any form of contain, such as “contains” and “containing”) are open-ended linking verbs. As a result, a surgical system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more elements possesses those one or more elements, but is not limited to possessing only those one or more elements. Likewise, an element of a system, device, or apparatus that “comprises,” “has,” “includes” or “contains” one or more features possesses those one or more features, but is not limited to possessing only those one or more features.

The terms “proximal” and “distal” are used herein with reference to a clinician manipulating the handle portion of the surgical instrument. The term “proximal” refers to the portion closest to the clinician and the term “distal” refers to the portion located away from the clinician. It will be further appreciated that, for convenience and clarity, spatial terms such as “vertical”, “horizontal”, “up”, and “down” may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performing laparoscopic and minimally invasive surgical procedures. However, the reader will readily appreciate that the various methods and devices disclosed herein can be used in numerous surgical procedures and applications including, for example, in connection with open surgical procedures. As the present Detailed Description proceeds, the reader will further appreciate that the various instruments disclosed herein can be inserted into a body in any way, such as through a natural orifice, through an incision or puncture hole formed in tissue, etc. The working portions or end effector portions of the instruments can be inserted directly into a patient's body or can be inserted through an access device that has a working channel through which the end effector and elongate shaft of a surgical instrument can be advanced.

A surgical stapling system can comprise a shaft and an end effector extending from the shaft. The end effector comprises a first jaw and a second jaw. The first jaw comprises a staple cartridge. The staple cartridge is insertable into and removable from the first jaw; however, other embodiments are envisioned in which a staple cartridge is not removable from, or at least readily replaceable from, the first jaw. The second jaw comprises an anvil configured to deform staples ejected from the staple cartridge. The second jaw is pivotable relative to the first jaw about a closure axis; however, other embodiments are envisioned in which the first jaw is pivotable relative to the second jaw. The surgical stapling system further comprises an articulation joint configured to permit the end effector to be rotated, or articulated, relative to the shaft. The end effector is rotatable about an articulation axis extending through the articulation joint. Other embodiments are envisioned which do not include an articulation joint.

The staple cartridge comprises a cartridge body. The cartridge body includes a proximal end, a distal end, and a deck extending between the proximal end and the distal end. In use, the staple cartridge is positioned on a first side of the tissue to be stapled and the anvil is positioned on a second side of the tissue. The anvil is moved toward the staple cartridge to compress and clamp the tissue against the deck. Thereafter, staples removably stored in the cartridge body can be deployed into the tissue. The cartridge body includes staple cavities defined therein wherein staples are removably stored in the staple cavities. The staple cavities are arranged in six longitudinal rows. Three rows of staple cavities are positioned on a first side of a longitudinal slot and three rows of staple cavities are positioned on a second side of the longitudinal slot. Other arrangements of staple cavities and staples may be possible.

The staples are supported by staple drivers in the cartridge body. The drivers are movable between a first, or unfired position, and a second, or fired, position to eject the staples from the staple cavities. The drivers are retained in the cartridge body by a retainer which extends around the bottom of the cartridge body and includes resilient members configured to grip the cartridge body and hold the retainer to the cartridge body. The drivers are movable between their unfired positions and their fired positions by a sled. The sled is movable between a proximal position adjacent the proximal end and a distal position adjacent the distal end. The sled comprises a plurality of ramped surfaces configured to slide under the drivers and lift the drivers, and the staples supported thereon, toward the anvil.

Further to the above, the sled is moved distally by a firing member. The firing member is configured to contact the sled and push the sled toward the distal end. The longitudinal slot defined in the cartridge body is configured to receive the firing member. The anvil also includes a slot configured to receive the firing member. The firing member further comprises a first cam which engages the first jaw and a second cam which engages the second jaw. As the firing member is advanced distally, the first cam and the second cam can control the distance, or tissue gap, between the deck of the staple cartridge and the anvil. The firing member also comprises a knife configured to incise the tissue captured intermediate the staple cartridge and the anvil. It is desirable for the knife to be positioned at least partially proximal to the ramped surfaces such that the staples are ejected ahead of the knife.

FIG. 1 depicts a motor-driven (electromechanical) surgical system 1 that may be used to perform a variety of different surgical procedures. As can be seen in that Figure, one example of the surgical system 1 includes a powered handheld electromechanical surgical instrument 100 that is configured for selective attachment thereto of a plurality of different surgical tool implements (referred to herein as “adapters”) that are each configured for actuation and manipulation by the powered handheld electromechanical surgical instrument. As illustrated in FIG. 1, the handheld surgical instrument 100 is configured for selective connection with an adapter 200, and, in turn, adapter 200 is configured for selective connection with end effectors that comprise a single use loading unit (“SULU”) or a disposable loading unit (“DLU”) or a multiple use loading unit (“MULU”). In another surgical system embodiment, various forms of adapter 200 may also be effectively employed with a tool drive assembly of a robotically controlled or automated surgical system. For example, the surgical tool assemblies disclosed herein may be employed with various robotic systems, instruments, components and methods such as, but not limited to, those disclosed in U.S. Pat. No. 9,072,535, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, which is hereby incorporated by reference herein in its entirety.

As illustrated in FIGS. 1 and 2, surgical instrument 100 includes a power-pack 101 and an outer shell housing 10 that is configured to selectively receive and substantially encase the power-pack 101. The power pack 101 may also be referred to herein as handle assembly 101. One form of surgical instrument 100, for example, is disclosed in International Publication No. WO 2016/057225 A1, International Application No. PCT/US2015/051837, entitled HANDHELD ELECTROMECHANICAL SURGICAL SYSTEM, the entire disclosure of which is hereby incorporated by reference herein. Various features of surgical instrument 100 will not be disclosed herein beyond what is necessary to understand the various features of the inventions disclosed herein with it being understood that further details may be gleaned from reference to WO 2016/057225 and other references incorporated by reference herein.

As illustrated in FIG. 3, outer shell housing 10 includes a distal half-section 10 a and a proximal half-section 10 b that is pivotably connected to distal half-section 10 a by a hinge 16 located along an upper edge of distal half-section 10 a and proximal half-section 10 b. When joined, distal and proximal half-sections 10 a, 10 b define a shell cavity 10 c therein in which the power-pack 101 is selectively situated. Each of distal and proximal half-sections 10 a, 10 b includes a respective upper shell portion 12 a, 12 b, and a respective lower shell portion 14 a, 14 b. Lower shell portions 14 a, 14 b define a snap closure feature 18 for selectively securing the lower shell portions 14 a, 14 b to one another and for maintaining shell housing 10 in a closed condition. Distal half-section 10 a of shell housing 10 defines a connecting portion 20 that is configured to accept a corresponding drive coupling assembly 210 of adapter 200 (see FIG. 5). Specifically, distal half-section 10 a of shell housing 10 has a recess that receives a portion of drive coupling assembly 210 of adapter 200 when adapter 200 is mated to surgical instrument 100.

Connecting portion 20 of distal half-section 10 a defines a pair of axially extending guide rails 21 a, 21 b that project radially inward from inner side surfaces thereof as shown in FIG. 5. Guide rails 21 a, 21 b assist in rotationally orienting adapter 200 relative to surgical instrument 100 when adapter 200 is mated to surgical instrument 100. Connecting portion 20 of distal half-section 10 a defines three apertures 22 a, 22 b, 22 c that are formed in a distally facing surface thereof and which are arranged in a common plane or line with one another. Connecting portion 20 of distal half-section 10 a also defines an elongate slot 24 also formed in the distally facing surface thereof. Connecting portion 20 of distal half-section 10 a further defines a female connecting feature 26 (see FIG. 2) formed in a surface thereof. Female connecting feature 26 selectively engages with a male connecting feature of adapter 200.

Distal half-section 10 a of shell housing 10 supports a distal facing toggle control button 30. The toggle control button 30 is capable of being actuated in a left, right, up and down direction upon application of a corresponding force thereto or a depressive force thereto. Distal half-section 10 a of shell housing 10 supports a right-side pair of control buttons 32 a, 32 b (see FIG. 3); and a left-side pair of control button 34 a, 34 b (see FIG. 2). The right-side control buttons 32 a, 32 b and the left-side control buttons 34 a, 34 b are capable of being actuated upon application of a corresponding force thereto or a depressive force thereto. Proximal half-section 10 b of shell housing 10 supports a right-side control button 36 a (see FIG. 3) and a left-side control button 36 b (see FIG. 2). Right-side control button 36 a and left-side control button 36 b are capable of being actuated upon application of a corresponding force thereto or a depressive force thereto.

Shell housing 10 includes a sterile barrier plate assembly 60 selectively supported in distal half-section 10 a. Specifically, the sterile barrier plate assembly 60 is disposed behind connecting portion 20 of distal half-section 10 a and within shell cavity 10 c of shell housing 10. The plate assembly 60 includes a plate 62 rotatably supporting three coupling shafts 64 a, 64 b, 64 c (see FIGS. 3 and 5). Each coupling shaft 64 a, 64 b, 64 c extends from opposed sides of plate 62 and has a tri-lobe transverse cross-sectional profile. Each coupling shaft 64 a, 64 b, 64 c extends through the respective apertures 22 a, 22 b, 22 c of connecting portion 20 of distal half-section 10 a when the sterile barrier plate assembly 60 is disposed within shell cavity 10 c of shell housing 10. The plate assembly 60 further includes an electrical pass-through connector 66 supported on plate 62. Pass-through connector 66 extends from opposed sides of plate 62. Pass-through connector 66 defines a plurality of contact paths each including an electrical conduit for extending an electrical connection across plate 62. When the plate assembly 60 is disposed within shell cavity 10 c of shell housing 10, distal ends of coupling shaft 64 a, 64 b, 64 c and a distal end of pass-through connector 66 are disposed or situated within connecting portion 20 of distal half-section 10 a of shell housing 10, and are configured to electrically and/or mechanically engage respective corresponding features of adapter 200.

Referring to FIGS. 3 and 4, the power-pack or the handle assembly 101 includes an inner handle housing 110 having a lower housing portion 104 and an upper housing portion 108 extending from and/or supported on lower housing portion 104. Lower housing portion 104 and upper housing portion 108 are separated into a distal half section 110 a and a proximal half-section 110 b connectable to distal half-section 110 a by a plurality of fasteners. When joined, distal and proximal half-sections 110 a, 110 b define the inner handle housing 110 having an inner housing cavity 110 c therein in which a power-pack core assembly 106 is situated. Power-pack core assembly 106 is configured to control the various operations of surgical instrument 100.

Distal half-section 110 a of inner handle housing 110 supports a distal toggle control interface 130 that is in operative registration with the distal toggle control button 30 of shell housing 10. In use, when the power-pack 101 is disposed within shell housing 10, actuation of the toggle control button 30 exerts a force on toggle control interface 130. Distal half-section 110 a of inner handle housing 110 also supports a right-side pair of control interfaces (not shown), and a left-side pair of control interfaces 132 a, 132 b. In use, when the power-pack 101 is disposed within shell housing 10, actuation of one of the right-side pair of control buttons or the left-side pair of control button of distal half-section 10 a of shell housing 10 exerts a force on a respective one of the right-side pair of control interfaces 132 a, 132 b or the left-side pair of control interfaces 132 a, 132 b of distal half-section 110 a of inner handle housing 110.

With reference to FIGS. 1-5, inner handle housing 110 provides a housing in which power-pack core assembly 106 is situated. Power-pack core assembly 106 includes a battery circuit 140, a controller circuit board 142 and a rechargeable battery 144 configured to supply power to any of the electrical components of surgical instrument 100. Controller circuit board 142 includes a motor controller circuit board 142 a, a main controller circuit board 142 b, and a first ribbon cable 142 c interconnecting motor controller circuit board 142 a and main controller circuit board 142 b. Power-pack core assembly 106 further includes a display screen 146 supported on main controller circuit board 142 b. Display screen 146 is visible through a clear or transparent window 110 d (see FIG. 3) provided in proximal half-section 110 b of inner handle housing 110. It is contemplated that at least a portion of inner handle housing 110 may be fabricated from a transparent rigid plastic or the like. It is further contemplated that shell housing 10 may either include a window formed therein (in visual registration with display screen 146 and with window 110 d of proximal half-section 110 b of inner handle housing 110, and/or shell housing 10 may be fabricated from a transparent rigid plastic or the like.

Power-pack core assembly 106 further includes a first motor 152, a second motor 154, and a third motor 156 that are supported by motor bracket 148 and are each electrically connected to controller circuit board 142 and battery 144. Motors 152, 154, 156 are disposed between motor controller circuit board 142 a and main controller circuit board 142 b. Each motor 152, 154, 156 includes a respective motor shaft 152 a, 154 a, 156 a extending therefrom. Each motor shaft 152 a, 154 a, 156 a has a tri-lobe transverse cross-sectional profile for transmitting rotative forces or torque. Each motor 152, 154, 156 is controlled by a respective motor controller. Rotation of motor shafts 152 a, 154 a, 156 a by respective motors 152, 154, 156 function to drive shafts and/or gear components of adapter 200 in order to perform the various operations of surgical instrument 100. In particular, motors 152, 154, 156 of power-pack core assembly 106 are configured to drive shafts and/or gear components of adapter 200.

As illustrated in FIGS. 1 and 5, surgical instrument 100 is configured for selective connection with adapter 200, and, in turn, adapter 200 is configured for selective connection with end effector 500. Adapter 200 includes an outer knob housing 202 and an outer tube 206 that extends from a distal end of knob housing 202. Knob housing 202 and outer tube 206 are configured and dimensioned to house the components of adapter assembly 200. Outer tube 206 is dimensioned for endoscopic insertion, in particular, that outer tube is passable through a typical trocar port, cannula or the like. Knob housing 202 is dimensioned to not enter the trocar port, cannula of the like. Knob housing 202 is configured and adapted to connect to connecting portion 20 of the outer shell housing 10 of surgical instrument 100.

Adapter 200 is configured to convert a rotation of either of first or second coupling shafts 64 a, 64 b of surgical instrument 100 into axial translation useful for operating a drive assembly 540 and an articulation link 560 of end effector 500, as illustrated in FIG. 10 and as will be described in greater detail below. As illustrated in FIG. 6, adapter 200 includes the proximal inner housing assembly 204 that rotatably supports a first rotatable proximal drive shaft 212, a second rotatable proximal drive shaft 214, and a third rotatable proximal drive shaft 216 therein. Each proximal drive shaft 212, 214, 216 functions as a rotation receiving member to receive rotational forces from respective coupling shafts 64 a, 64 b and 64 c of surgical instrument 100. In addition, the drive coupling assembly 210 of adapter 200 is also configured to rotatably support first, second and third connector sleeves 218, 220 and 222, respectively, arranged in a common plane or line with one another. Each connector sleeve 218, 220, 222 is configured to mate with respective first, second and third coupling shafts 64 a, 64 b, 64 c of surgical instrument 100, as described above. Each connector sleeves 218, 222, 220 is further configured to mate with a proximal end of respective first, second, and third proximal drive shafts 212, 214, 216 of adapter 200.

Drive coupling assembly 210 of adapter 200 also includes a first, a second, and a third biasing member 224, 226, and 228 disposed distally of respective first, second, and third connector sleeves 218, 220, 222. Each biasing members 224, 226, and 228 is disposed about respective first, second, and third rotatable proximal drive shaft 212, 214, and 216. Biasing members 224, 226, and 228 act on respective connector sleeves 218, 222, and 220 to help maintain connector sleeves 218, 222, and 220 engaged with the distal end of respective coupling shafts 64 a, 64 b, and 64 c of surgical instrument 100 when adapter 200 is connected to surgical instrument 100.

Also in the illustrated arrangement, adapter 200 includes first, second, and third drive converting assemblies 240, 250, 260, respectively, that are each disposed within inner housing assembly 204 and outer tube 206. Each drive converting assembly 240, 250, 260 is configured and adapted to transmit or convert a rotation of a first, second, and third coupling shafts 64 a, 64 b, and 64 c of surgical instrument 100 into axial translation of an articulation driver or bar 258 of adapter 200, to effectuate articulation of end effector 500; a rotation of a ring gear 266 of adapter 200, to effectuate rotation of adapter 200; or axial translation of a distal drive member 248 of adapter 200 to effectuate closing, opening, and firing of end effector 500.

Still referring to FIG. 6, first force/rotation transmitting/converting assembly 240 includes first rotatable proximal drive shaft 212, which, as described above, is rotatably supported within inner housing assembly 204. First rotatable proximal drive shaft 212 includes a non-circular or shaped proximal end portion configured for connection with first connector sleeve 218 which is connected to respective first coupling shaft 64 a of surgical instrument 100. First rotatable proximal drive shaft 212 includes a threaded distal end portion 212 b. First force/rotation transmitting/converting assembly 240 further includes a drive coupling nut 244 that threadably engages the threaded distal end portion 212 b of first rotatable proximal drive shaft 212, and which is slidably disposed within outer tube 206. Drive coupling nut 244 is slidably keyed within proximal core tube portion of outer tube 206 so as to be prevented from rotation as first rotatable proximal drive shaft 212 is rotated. In this manner, as the first rotatable proximal drive shaft 212 is rotated, drive coupling nut 244 is translated along threaded distal end portion 212 b of first rotatable proximal drive shaft 212 and, in turn, through and/or along outer tube 206.

First force/rotation transmitting/converting assembly 240 further includes a distal drive member 248 that is mechanically engaged with drive coupling nut 244, such that axial movement of drive coupling nut 244 results in a corresponding amount of axial movement of distal drive member 248. The distal end portion of distal drive member 248 supports a connection member 247 configured and dimensioned for selective engagement with an engagement member 546 of a drive assembly 540 of end effector 500 (FIG. 10). Drive coupling nut 244 and/or distal drive member 248 function as a force transmitting member to components of end effector 500. In operation, as first rotatable proximal drive shaft 212 is rotated, as a result of the rotation of first coupling shaft 64 a of surgical instrument 100, drive coupling nut 244 is translated axially along first rotatable proximal drive shaft 212. As drive coupling nut 244 is translated axially along first rotatable proximal drive shaft 212, distal drive member 248 is translated axially relative to outer tube 206. As distal drive member 248 is translated axially, with connection member 247 connected thereto and engaged with a hollow drive member 548 attached to drive assembly 540 of end effector 500 (FIG. 10), distal drive member 248 causes concomitant axial translation of drive assembly 540 of end effector 500 to effectuate a closure of a tool assembly portion 600 of the end effector 500 and a firing of various components within the tool assembly.

Still referring to FIG. 6, second drive converting assembly 250 of adapter 200 includes second proximal drive shaft 214 that is rotatably supported within inner housing assembly 204. Second rotatable proximal drive shaft 214 includes a non-circular or shaped proximal end portion configured for connection with second coupling shaft 64 c of surgical instrument 100. Second rotatable proximal drive shaft 214 further includes a threaded distal end portion 214 a configured to threadably engage an articulation bearing housing 253 of an articulation bearing assembly 252. Referring to FIGS. 6-9, the articulation bearing housing 253 supports an articulation bearing 255 that has an inner race 257 that is independently rotatable relative to an outer race 259. Articulation bearing housing 253 has a non-circular outer profile, for example tear-dropped shaped, that is slidably and non-rotatably disposed within a complementary bore (not shown) of inner housing hub 204 a. Second drive converting assembly 250 of adapter 200 further includes articulation bar 258 that has a proximal portion that is secured to inner race 257 of articulation bearing 255. A distal portion of articulation bar 258 includes a slot 258 a therein, which is configured to accept a hook 562 the articulation link 560 (FIG. 10) of end effector 500. Articulation bar 258 functions as a force transmitting member to components of end effector 500. In the illustrated arrangement and as further discussed in WO 2016/057225 A1, articulation bearing assembly 252 is both rotatable and longitudinally translatable and is configured to permit free, unimpeded rotational movement of end effector 500 when its first and second jaw members 610, 700 are in an approximated position and/or when jaw members 610, 700 are articulated.

In operation, as second proximal drive shaft 214 is rotated, the articulation bearing assembly 252 is axially translated along threaded distal end portion 214 a of second proximal drive shaft 214, which in turn, causes articulation bar 258 to be axially translated relative to outer tube 206. As articulation bar 258 is translated axially, articulation bar 258, being coupled to articulation link 560 of end effector 500, causes concomitant axial translation of articulation link 560 of end effector 500 to effectuate an articulation of tool assembly 600. Articulation bar 258 is secured to inner race 257 of articulation bearing 253 and is thus free to rotate about the longitudinal axis relative to outer race 259 of articulation bearing 253.

As illustrated in FIG. 6, adapter 200 includes a third drive converting assembly 260 that is supported in inner housing assembly 204. Third drive converting assembly 260 includes rotation ring gear 266 that is fixedly supported in and connected to outer knob housing 202. Ring gear 266 defines an internal array of gear teeth 266 a and includes a pair of diametrically opposed, radially extending protrusions 266 b. Protrusions 266 b are configured to be disposed within recesses defined in outer knob housing 202, such that rotation of ring gear 266 results in rotation of outer knob housing 202, and vice a versa. Third drive converting assembly 260 further includes third rotatable proximal drive shaft 216 which, as described above, is rotatably supported within inner housing assembly 204. Third rotatable proximal drive shaft 216 includes a non-circular or shaped proximal end portion that is configured for connection with third connector 220. Third rotatable proximal drive shaft 216 includes a spur gear 216 keyed to a distal end thereof. A reversing spur gear 264 inter-engages spur gear 216 a of third rotatable proximal drive shaft 216 to gear teeth 266 a of ring gear 266. In operation, as third rotatable proximal drive shaft 216 is rotated, due to a rotation of the third coupling shaft 64 b of surgical instrument 100, spur gear 216 a of third rotatable proximal drive shaft 216 engages reversing gear 264 causing reversing gear 264 to rotate. As reversing gear 264 rotates, ring gear 266 also rotates thereby causing outer knob housing 202 to rotate. Rotation of the outer knob housing 202 causes the outer tube 206 to rotate about longitudinal axis of adapter 200. As outer tube 206 is rotated, end effector 500 that is connected to a distal end portion of adapter 200, is also rotated about a longitudinal axis of adapter 200.

Adapter 200 further includes an attachment/detachment button 272 (FIG. 5) that is supported on a stem 273 (FIG. 6) that projects from drive coupling assembly 210 of adapter 200. The attachment/detachment button 272 is biased by a biasing member (not shown) that is disposed within or around stem 273, to an un-actuated condition. Button 272 includes a lip or ledge that is configured to snap behind a corresponding lip or ledge of connecting portion 20 of the surgical instrument 100. As also discussed in WO 2016/057225 A1, the adapter 200 may further include a lock mechanism 280 for fixing the axial position of distal drive member 248. As can be seen in FIG. 21, for example, lock mechanism 280 includes a button 282 that is slidably supported on outer knob housing 202. Lock button 282 is connected to an actuation bar (not shown) that extends longitudinally through outer tube 206. Actuation bar moves upon a movement of lock button 282. In operation, in order to lock the position and/or orientation of distal drive member 248, a user moves lock button 282 from a distal position to a proximal position, thereby causing the lock out (not shown) to move proximally such that a distal face of the lock out moves out of contact with camming member 288, which causes camming member 288 to cam into recess 249 of distal drive member 248. In this manner, distal drive member 248 is prevented from distal and/or proximal movement. When lock button 282 is moved from the proximal position to the distal position, the distal end of actuation bar moves distally into the lock out (not shown), against the bias of a biasing member (not shown), to force camming member 288 out of recess 249, thereby allowing unimpeded axial translation and radial movement of distal drive member 248.

Returning again to FIG. 6, adapter 200 includes an electrical assembly 290 supported on and in outer knob housing 202 and inner housing assembly 204. Electrical assembly 290 includes a plurality of electrical contact blades 292, supported on a circuit board 294, for electrical connection to pass-through connector of plate assembly of shell housing 10 of surgical instrument 100. Electrical assembly 290 serves to allow for calibration and communication information (i.e., life-cycle information, system information, force information) to pass to the circuit board of surgical instrument 100 via an electrical receptacle portion of the power-pack core assembly 106 of surgical instrument 100. Electrical assembly 290 further includes a strain gauge 296 that is electrically connected to circuit board 294. Strain gauge 296 is mounted within the inner housing assembly 204 to restrict rotation of the strain gauge 296 relative thereto. First rotatable proximal drive shaft 212 extends through strain gauge 296 to enable the strain gauge 296 to provide a closed-loop feedback to a firing/clamping load exhibited by first rotatable proximal drive shaft 212. Electrical assembly 290 also includes a slip ring 298 that is non-rotatably and slidably disposed along drive coupling nut 244 of outer tube 206. Slip ring 298 is in electrical connection with circuit board 294 and serves to permit rotation of first rotatable proximal drive shaft 212 and axial translation of drive coupling nut 244 while still maintaining electrical contact of slip ring 298 with at least another electrical component within adapter 200, and while permitting the other electrical components to rotate about first rotatable proximal drive shaft 212 and drive coupling nut 244.

Still referring to FIG. 6, inner housing assembly 204 includes a hub 205 that has a distally oriented annular wall 207 that defines a substantially circular outer profile. Hub 205 includes a substantially tear-drop shaped inner recess or bore that is shaped and dimensioned to slidably receive articulation bearing assembly 252 therewithin. Inner housing assembly 204 further includes a ring plate 254 that is secured to a distal face of distally oriented annular wall 207 of hub 204 a. Ring plate 254 defines an aperture 254 a therethrough that is sized and formed therein so as to be aligned with second proximal drive shaft 214 and to rotatably receive a distal tip thereof. In this manner, the distal tip of the second proximal drive shaft 214 is supported and prevented from moving radially away from a longitudinal rotational axis of second proximal drive shaft 214 as second proximal drive shaft 214 is rotated to axially translate articulation bearing assembly 252.

Turning next to FIG. 10, in one example, the end effector 500 may be configured for a single use (“disposable loading unit—DLU”) and be similar to those DLU's disclosed in U.S. Patent Application Publication No. US 2010/0301097, entitled LOADING UNIT HAVING DRIVE ASSEMBLY LOCKING MECHANISM, U.S. Patent Application Publication No. US 2012/0217284, entitled LOCKING MECHANISM FOR USE WITH LOADING UNITS, and U.S. Patent Application Publication No. US 2015/0374371, entitled ADAPTER ASSEMBLIES FOR INTERCONNECTING SURGICAL LOADING UNITS AND HANDLE ASSEMBLIES, the entire disclosures of each such references being hereby incorporated by reference herein. It is also contemplated that the end effector 500 may be configured for multiple uses (MULU) such as those end effectors disclosed in US Patent Application Publication No. US 2017/0095250, entitled MULTI-USE LOADING UNIT, the entire disclosure of which is hereby incorporated by reference herein.

The depicted surgical instrument 100 fires staples, but it may be adapted to fire any other suitable fastener such as clips and two-part fasteners. In the illustrated arrangement, the end effector 500 comprises a loading unit 510. The loading unit 510 comprises a proximal body portion 520 and a tool assembly 600. Tool assembly 600 includes a pair of jaw members including a first jaw member 610 that comprises an anvil assembly 612 and a second jaw member 700 that comprises a cartridge assembly 701. One jaw member is pivotal in relation to the other to enable the clamping of tissue between the jaw members. The cartridge assembly 701 is movable in relation to anvil assembly 612 and is movable between an open or unclamped position and a closed or approximated position. However, the anvil assembly 612, or both the cartridge assembly 701 and the anvil assembly 612, can be movable.

The cartridge assembly 701 has a cartridge body 702 and in some instances a support plate 710 that are attached to a channel 720 by a snap-fit connection, a detent, latch, or by another type of connection. The cartridge assembly 701 includes fasteners or staples 704 that are movably supported in a plurality of laterally spaced staple retention slots 706, which are configured as openings in a tissue contacting surface 708. Each slot 706 is configured to receive a fastener or staple therein. Cartridge body 702 also defines a plurality of cam wedge slots which accommodate staple pushers 709 and which are open on the bottom (i.e., away from tissue-contacting surface) to allow an actuation sled 712 to pass longitudinally therethrough. The cartridge assembly 701 is removable from channel 720 after the staples have been fired from cartridge body 702. Another removable cartridge assembly is capable of being loaded onto channel 720, such that surgical instrument 100 can be actuated again to fire additional fasteners or staples. Further details concerning the cartridge assembly may be found, for example, in US Patent Application Publication No. US2017/0095250 as well as various other references that have been incorporated by reference herein.

Cartridge assembly 701 is pivotal in relation to anvil assembly 612 and is movable between an open or unclamped position and a closed or clamped position for insertion through a cannula of a trocar. Proximal body portion 520 includes at least a drive assembly 540 and an articulation link 560. In one arrangement, drive assembly 540 includes a flexible drive beam 542 that has a distal end 544 and a proximal engagement section 546. A proximal end of the engagement section 546 includes diametrically opposed inwardly extending fingers 547 that engage a hollow drive member 548 to fixedly secure drive member 548 to the proximal end of beam 542. Drive member 548 defines a proximal porthole which receives connection member 247 of drive tube 246 of first drive converting assembly 240 of adapter 200 when the end effector 500 is attached to the distal end of the adapter 200.

End effector 500 further includes a housing assembly 530 that comprises an outer housing 532 and an inner housing 534 that is disposed within outer housing 532. First and second lugs 536 are each disposed on an outer surface of a proximal end 533 of outer housing 532 and are configured to operably engage the distal end of the adapter 200 as discussed in further detail in WO 2016/057225 A1.

With reference to FIG. 10, for example, anvil assembly 612 includes an anvil cover 630 and an anvil plate 620, which includes a plurality of staple forming depressions. Anvil plate 620 is secured to an underside of anvil cover 630. When tool assembly 600 is in the approximated position, staple forming depressions are positioned in juxtaposed alignment with staple receiving slots of the cartridge assembly 701.

The tool assembly 600 includes a mounting assembly 800 that comprises an upper mounting portion 810 and a lower mounting portion 812. A mounting tail 632 protrudes proximally from a proximal end 631 of the anvil cover 630. A centrally-located pivot member 814 extends from each upper and lower mounting portions 810 and 812 through openings 822 that are formed in coupling members 820. In at least one arrangement, the pivot member 814 of the upper mounting portion 810 also extends through an opening 634 in the mounting tail 632 as well. Coupling members 820 each include an interlocking proximal portion 824 that is configured to be received in corresponding grooves formed in distal ends of the outer housing 532 and inner housing 534. Proximal body portion 520 of end effector 500 includes articulation link 560 that has a hooked proximal end 562. The articulation link 560 is dimensioned to be slidably positioned within a slot in the inner housing. A pair of H-block assemblies 830 are positioned adjacent the distal end of the outer housing 532 and adjacent the distal end 544 of axial drive assembly 540 to prevent outward buckling and bulging of the flexible drive beam 542 during articulation and firing of surgical stapling apparatus 10. Each H-block assembly 830 includes a flexible body 832 which includes a proximal end fixedly secured to the distal end of the outer housing 532 and a distal end that is fixedly secured to mounting assembly 800. In one arrangement, a distal end 564 of the articulation link is pivotally pinned to the right H block assembly 830. Axial movement of the articulation link 560 will cause the tool assembly to articulate relative to the body portion 520.

FIGS. 11-15 illustrate an adapter 200′ that is substantially identical to adapter 200 described above, except for the differences noted below. As can be seen in FIG. 11, the adapter 200′ includes an outer tube 206 that has a proximal end portion 910 that has a first diameter “FD” and is mounted within the outer knob housing 202. The proximal end portion 910 may be coupled to the inner housing assembly 204 or otherwise supported therein in the manners discussed in further detail in WO 2016/057225 A1 for example. The proximal end portion 910 extends proximally from a central tube portion 912 that has a second diameter “SD”. In the illustrated embodiment, an end effector 500 is coupled to a distal end 914 of a shaft assembly 203 or outer tube 206. The outer tube 206 defines a longitudinal axis LA that extends between the proximal end portion 910 and the distal end 914 as can be seen in FIG. 11. As can be seen in FIGS. 10 and 11, an outer sleeve 570 of the proximal body portion 520 of the end effector 500 has a distal end portion 572 and a proximal end portion 574. The proximal end portion 574 has a diameter SD′ that is approximately equal to the second diameter SD of the central tube portion 912. The distal end portion 572 has a third diameter “TD”. In one arrangement, FD and TD are approximately equal and greater than SD. Other arrangements are contemplated wherein FD and TD are not equal, but each are greater than SD. However, it is preferable that for most cases FD and TD are dimensioned for endoscopic insertion through a typical trocar port, cannula or the like. In at least one arrangement (FIG. 11), the outer sleeve 570 is formed with a flat or scalloped side 576 to facilitate improved access within the patient while effectively accommodating the various drive and articulation components of the adapter 200′. In addition, by providing the central tube portion 912 with a reduced diameter may afford the adapter 200′ with improved thoracic in-between rib access.

In at least one arrangement, channel 720, which may be machined or made of sheet metal, includes a pair of proximal holes 722 (FIG. 10) that are configured to align with a pair of corresponding holes 636 in the anvil cover 630 to receive corresponding pins or bosses 638 (FIG. 12) to facilitate a pivotal relationship between anvil assembly 612 and cartridge assembly 701. In the illustrated example, a dynamic clamping assembly 550 is attached to or formed at the distal end 544 of the flexible drive beam 542. The dynamic clamping assembly 550 includes a vertical body portion 552 that has a tissue cutting surface 554 formed thereon or attached thereto. See FIG. 10, for example. An anvil engagement feature 556 is formed on one end of the body portion 552 and comprises an anvil engagement tab 557 that protrudes from each lateral side of the body portion 552. Similarly, a channel engagement feature 558 is formed on the other end of the of the body portion 552 and comprises a channel engagement tab 559 that protrudes from each lateral side of the body portion 552. See FIG. 15.

As indicated above, the anvil assembly 612 includes an anvil plate 620. The anvil plate 620 includes an elongate slot 622 that is configured to accommodate the body portion 552 of the dynamic clamping assembly 550 as the dynamic clamping assembly 550 is axially advanced during the firing process. The elongate slot 622 is defined between two anvil plate ledges 624 that extend along each lateral side of the elongate slot 622. See FIG. 10. As the dynamic clamping assembly 550 is distally advanced, the anvil engagement tabs 557 slidably engage the anvil plate ledges 624 to retain the anvil assembly 612 clamped onto the target tissue. Similarly, during the firing operation, the body portion 552 of the dynamic clamping assembly 550 extends through a central slot in the channel 720 and the channel engagement tabs 559 slidably engage channel ledges 725 extending along each side of the central channel slot to retain the cartridge assembly 701 clamped onto the target tissue.

Turning to FIGS. 13 and 15, the channel 720 defines a docking area generally designated as 730 that is configured to accommodate the dynamic clamping assembly 550 when it is in its proximal most position referred to herein as an unfired or starting position. In particular, the docking area 730 is partially defined by planar docking surfaces 732 that provides clearance between the channel engagement tabs 559 on the dynamic clamping assembly 550 to enable the cartridge assembly 701 to pivot to a fully opened position. A ramped or camming surface 726 extends from a distal end of each of the docking surfaces 732. Ramped surface 726 is engaged by the dynamic clamping assembly 550 in order to move the anvil assembly 612 and the cartridge assembly 701 with respect to one another. Similar camming surface could be provided on the anvil assembly 612 in other embodiments. It is envisioned that ramped surfaces 726 may also facilitate the alignment and/or engagement between channel 720 and support plate 620 and/or cartridge body 702. As the drive assembly 540 is distally advanced (fired), the channel engagement tabs 559 on the dynamic clamping assembly 550 engage the corresponding ramped surfaces 726 to apply a closing motion to the cartridge assembly 701 thus closing the cartridge assembly 701 and the anvil assembly 612. Further distal translation of the dynamic clamping assembly 550 causes the actuation sled 712 to move distally through cartridge body 702, which causes cam wedges 713 of actuation sled 712 to sequentially engage staple pushers 709 to move staple pushers 709 vertically within staple retention slots 706 and eject staples 704 into staple forming depressions of anvil plate 620. Subsequent to the ejection of staples 704 from retention slots 706 (and into tissue), the cutting edge 554 of the dynamic clamping assembly 550 severs the stapled tissue as the tissue cutting edge 554 on the vertical body portion 552 of the dynamic clamping assembly 550 travels distally through a central slot 703 of cartridge body 702. After staples 704 have been ejected from cartridge body 702 and a user wishes to use the same instrument 10 to fire additional staples 704 (or another type of fastener or knife), the user can remove the loading unit 510 from the adapter 200′ and replace it with another fresh or unspent loading unit. In an alternative arrangement, the user may simply remove the spent cartridge body 702 and replace it with a fresh unspent or unfired cartridge body 702.

The surgical instrument 100 can include sensor assemblies for detecting various states and/or parameters associated with the operation of the surgical instrument 100. A control circuit or processor can monitor these sensed states and/or parameters and then control the operation of the surgical instrument 100 accordingly. For example, the surgical instrument 100 can monitor the current drawn by the motor driving the first force/rotation transmitting/converting assembly 240 (FIG. 6) in order to control the speed at which the clamping member 550 (FIG. 10) is translated. As another example, the surgical instrument 100 can monitor the gap or distance between the jaw members or the anvil plate 620 (FIG. 10) and the cartridge body 702 (FIG. 10) when the end effector 500 is clamped in order to control the speed at which the clamping member 550 is driven thereafter. These and other sensor assemblies with corresponding logic executed by a control circuit or processor in conjunction with the sensor assemblies are described herebelow.

FIGS. 16 and 17 illustrate schematic diagrams a circuit 2000 for controlling a motor 2010 of a surgical instrument, according to various aspects of the present disclosure. In the depicted aspects, the circuit 2000 includes a switch 2002, a first limit switch 2004 (e.g., a normally open switch), a second limit switch 2006 (e.g., a normally closed switch), a power source 2008, and a motor 2010 (e.g., a motor that is configured to drive the first force/rotation transmitting/converting assembly 240). The circuit 2002 can further include a first relay 2012 (e.g., a single-pole double-throw relay), a second relay 2014 (e.g., a single-pole single-throw relay), a third relay 2016 (e.g., a double-pole double-throw relay), a current sensor 2018, and a current detection module 2030. In one aspect, the circuit 2000 can include a motor control circuit 2028 that is configured to sense the electrical current through the motor 2010 and then control the current accordingly. In the aspect depicted in FIG. 16, the second relay 2014, the current sensor 2018, the position sensor 2020, and the current detection module 2030 collectively form the motor control circuit 2028. In the aspect depicted in FIG. 17, the second relay 2014, the current sensor 2018, the position sensor 2020, and the controller 2034 collectively form the motor control circuit 2028. As described below, the motor control circuit 2028 controls the current to the motor 2010 by interrupting the current based upon the sensed current, thus deactivating the motor 2010 when certain conditions occur.

The switch 2002 is activated when an operator of the surgical instrument 100 initiates the firing of the clamping member 550 to clamp the end effector 500 and cut and/or staple tissue. The first limit switch 2004 is configured to remain open when the cutting/stapling operation of the end effector 500 is not yet complete. When the first limit switch 2004 is open, the coil 2022 of first relay 2012 is de-energized, thus forming a conductive path between the power source 2008 and second relay 2014 via a normally-closed contact of relay 2012. The coil 2026 of the second relay 2014 is controlled by the current detection module 2030 and the position sensor 2020 as described below. When the coil 2026 of the second relay 2014 and the coil 2022 of the first relay 2022 are de-energized, a conductive path between the power source 2008 and a normally-closed contact of the third relay 2016 is formed. The third relay 2016 controls the rotational direction of the motor 2010 based on the states of switches 2004, 2006. When first limit switch 2004 is open and the second limit switch 2006 is closed (indicating that the clamping member 550 has not yet fully deployed distally), the coil 2024 of the third relay 2016 is de-energized. Accordingly, when coils 2022, 2024, 2026 are collectively de-energized, current from the power source 2008 flows through the motor 2010 via the normally-closed contacts of the third relay 2016 and causes the forward rotation of the motor 2010, which in turn causes the clamping member 550 to be driven distally by the motor 2010 to clamp the end effector 500 and cut and/or staple tissue.

When the clamping member 550 has been fully advanced distally, the first limit switch 2004 is configured to close. When the first limit switch 2004 is closed, the coil 2022 of the first relay 2012 is energized and the coil 2024 of third relay 2016 is energized via a normally open contact of relay 2012. Accordingly, current now flows to the motor 2010 via normally-open contacts of relays 2012, 2016, thus causing reverse rotation of the motor 2010 which in turn causes the clamping member 550 to retract from its distal position and the first limit switch 2004 to open. The second limit switch 2004 is configured to open when the clamping member 550 is fully retracted. Coil 2022 of relay 2012 remains energized until the second limit switch 2006 is opened, indicating the complete retraction of the clamping member 550.

The magnitude of current through the motor 2010 during its forward rotation is indicative of forces exerted upon the clamping member 550 as it is driven distally by the motor 2010. If a staple cartridge 702 is not loaded into the end effector 500, an incorrect staple cartridge 702 is loaded into the end effector 500, or if the clamping member 550 experiences unexpectedly high resistance from the tissue as it cuts and/or staples the tissue, the resistive force exerted against the clamping member 550 causes an increase in motor torque, which thereby causes the motor current to increase. If the motor current exceeds a threshold, the motor control circuit 2028 can cut off the electrical current to the motor 2010, deactivating the motor and thus pausing the advancement of the clamping member 550. Accordingly, by sensing the current through the motor 2010, the motor control circuit 2028 can differentiate between normal operational thresholds of the deployment of the clamping member 550 and potential error conditions.

The current sensor 2018 may be coupled to a path of the circuit 2000 that conducts current to the motor 2010 during its forward rotation. The current sensor 2018 may be any current sensing device (e.g., a shunt resistor, a Hall effect current transducer, etc.) suitable for generating a signal (e.g., a voltage signal) representative of sensed motor current. The generated signal may be input to the current detection module 2030 for processing therein. According to the aspect depicted in FIG. 16, the current detection module 2030 may be configured for comparing the signal generated by the current sensor 2018 to a threshold signal (e.g., a threshold voltage signal) via a comparator circuit 2032 for receiving the threshold and current sensor 2018 signals and generating a discrete output based on a comparison of the received signals. In some aspects, a value of the threshold signal may be empirically determined a priori by measuring the peak signal generated by the current sensor 2018 when the clamping member 550 is initially deployed (e.g., over an initial period or length of its distal movement) during a cutting and stapling operation. In other aspects, the value of the threshold signal can be a pre-determined value that can, in one example, be retrieved from a memory.

In some aspects, it may be desirable to limit the comparison of the sensed motor current to the threshold value to a particular position or range(s) of positions along the firing stroke of the clamping member 550. In these aspects, the motor control circuit 2028 further includes a position sensor 2020 that is configured to generate a signal indicative of the position of the clamping member 550 (or alternatively, a component of the second or third force/rotation transmitting/converting assemblies 250, 260 for aspects wherein the motor 2010 represented in FIGS. 16 and 17 drives the second or third force/rotation transmitting/converting assemblies 250, 260). The position sensor 2020 can include, for example, the position sensing assembly depicted in FIG. 18 and described in fuller detail below. The position sensor 2020 is connected in series with the comparator circuit 2032 (or the microcontroller 2034 of the aspect depicted in FIG. 17) to limit the comparison based on the position of the clamping member 550. Accordingly, if the signal generated by the current sensor 2018 exceeds the threshold signal (indicating that unexpectedly high resistance is being encountered by the clamping member 550) and the clamping member 550 is within a particular zone as determined by the position sensor 2020, the coil 2026 of the second relay 2014 will be energized. This causes normally-closed switch of the second relay 2014 to open, thereby interrupting current flow to the motor 2010 and pausing the advancement of the clamping member 550. In this way, if the threshold signal is exceeded when the position of the clamping member 550 is not at a position that activates the position sensor 2020, then the motor control circuit 2038 will not deactivate the motor 2010, regardless of the result of the comparison. In other aspects, the motor control circuit 2038 is configured to monitor the motor current along the entirety of the firing stroke of the clamping member 550. In these aspects, the motor control circuit 2038 lacks the position sensor 2020 (or the position sensor 2020 is deactivated) and the output of the comparator circuit 2032 (or the microcontroller 2034) is fed directly to the second relay 2014. Accordingly, if the signal generated by the current sensor 2018 exceeds the threshold signal at any point along the firing stroke of the clamping member 550, then current flow to the motor 2010 is interrupted, in the manner described above.

According to the aspect depicted in FIG. 17, the motor control circuit 2028 can include a processor-based microcontroller 2034 in lieu of the current detection module 2030 described above. Although not shown for purposes of clarity, the microcontroller 2034 may include components well known in the microcontroller art such as, for example, a processor, a random access memory (RAM) unit, an erasable programmable read-only memory (EPROM) unit, an interrupt controller unit, timer units, analog-to-digital conversion (ADC) and digital-to-analog conversion (DAC) units, and a number of general input/output (I/O) ports for receiving and transmitting digital and analog signals. In on example, the microcontroller 2034 includes motor controllers comprising A3930/31K motor drivers from Allegro Microsystems, Inc. The A3930/31K motor drivers are designed to control a 3-phase brushless DC (BLDC) motor with N-channel external power MOSFETs, such as the motors 152, 154, 156 (FIG. 4). Each of the motor controllers is coupled to a main controller disposed on the main controller circuit board 142 b (FIG. 4). The main controller is also coupled to memory, which is also disposed on the main controller circuit board 142 b (FIG. 4). In one example, the main controller comprises an ARM Cortex M4 processor from Freescale Semiconductor, Inc. which includes 1024 kilobytes of internal flash memory. The main controller communicates with the motor controllers through an FPGA, which provides control logic signals. The control logic of the motor controllers then outputs corresponding energization signals to their respective motors 152, 154, 156 using fixed frequency pulse width modulation (PWM).

The current sensor 2018 and the position sensor 2020 may be connected to analog and digital inputs, respectively, of the microcontroller 2034, and the coil 2026 of the second relay 2014 may be connected to a digital output of the microcontroller 2034. It will be appreciated that in aspects in which the output of the position sensor 2020 is an analog signal, the position sensor 2020 may be connected to an analog input instead. Additionally, although the circuit 2000 includes relays 2012, 2014, 2016, it will be appreciated that in other aspects the relay switching functionality may be replicated using solid state switching devices, software, and combinations thereof. In certain aspects, for example, instructions stored and executed in the microcontroller 2034 may be used to control solid state switched outputs of the microcontroller 2034. In such aspects, switches 2004, 2006 may be connected to digital inputs of the microcontroller 2034.

FIG. 18 illustrates a schematic diagram of a position sensor 2102 of a surgical instrument 100, according to one aspect of the present disclosure. The position sensor 2102 may be implemented as an AS5055EQFT single-chip magnetic rotary position sensor available from Austria Microsystems, AG. The position sensor 2102 is interfaced with the controller 2104 to provide an absolute positioning system 2100. The position sensor 2102 is a low-voltage and low-power component and includes four Hall effect elements 2106A, 2106B, 2106C, 2106D in an area 2120 of the position sensor 2102 that is located above a magnet that is coupled to a component of the surgical instrument 100. The magnet can be coupled to, for example, a drive shaft of the motor driving the first force/rotation transmitting/converting assembly 240, the proximal drive shaft 212 of the first force/rotation transmitting/converting assembly 240, or a gear assembly that is rotatably driven by the clamping member 550 as the clamping member 550 is translated. In other words, the magnet can be coupled to a component of the surgical instrument 100 such that the angular position of the magnet with respect to the Hall effect elements 2106A, 2106B, 2106C, 2106D corresponds to a longitudinal position of, for example, the clamping member 550. A high-resolution ADC 2108 and a smart power management controller 2112 are also provided on the chip. A CORDIC processor 2110 (for Coordinate Rotation Digital Computer), also known as the digit-by-digit method and Volder's algorithm, is provided to implement a simple and efficient algorithm to calculate hyperbolic and trigonometric functions that require only addition, subtraction, bitshift, and table lookup operations. The angle position, alarm bits, and magnetic field information are transmitted over a standard serial communication interface such as an SPI interface 2114 to the controller 2104. The position sensor 2102 provides 12 or 14 bits of resolution. The position sensor 2102 may be an AS5055 chip provided in a small QFN 16-pin 4×4×0.85 mm package.

The Hall effect elements 2106A, 2106B, 2106C, 2106D are located directly above the rotating magnet (not shown). The Hall effect is a well-known effect and for expediency will not be described in detail herein; however, generally, the Hall effect produces a voltage difference (the Hall voltage) across an electrical conductor transverse to an electric current in the conductor and a magnetic field perpendicular to the current. A Hall coefficient is defined as the ratio of the induced electric field to the product of the current density and the applied magnetic field. It is a characteristic of the material from which the conductor is made, since its value depends on the type, number, and properties of the charge carriers that constitute the current. In the AS5055 position sensor 2102, the Hall effect elements 2106A, 2106B, 2106C, 2106D are capable producing a voltage signal that is indicative of the absolute position of the magnet 1202 in terms of the angle over a single revolution of the magnet 1202. This value of the angle, which is unique position signal, is calculated by the CORDIC processor 2110 is stored onboard the AS5055 position sensor 2102 in a register or memory. The value of the angle that is indicative of the position of the magnet 1202 over one revolution is provided to the controller 2104 in a variety of techniques, for example, upon power up or upon request by the controller 2104.

The AS5055 position sensor 2102 requires only a few external components to operate when connected to the controller 2104. Six wires are needed for a simple application using a single power supply: two wires for power and four wires 2116 for the SPI interface 2114 with the controller 2104. A seventh connection can be added in order to send an interrupt to the controller 2104 to inform that a new valid angle can be read. Upon power-up, the AS5055 position sensor 2102 performs a full power-up sequence including one angle measurement. The completion of this cycle is indicated as an INT output 2118, and the angle value is stored in an internal register. Once this output is set, the AS5055 position sensor 2102 suspends to sleep mode. The controller 2104 can respond to the INT request at the INT output 2118 by reading the angle value from the AS5055 position sensor 2102 over the SPI interface 2114. Once the angle value is read by the controller 2104, the INT output 2118 is cleared again. Sending a “read angle” command by the SPI interface 2114 by the controller 2104 to the position sensor 2102 also automatically powers up the chip and starts another angle measurement. As soon as the controller 2104 has completed reading of the angle value, the INT output 2118 is cleared and a new result is stored in the angle register. The completion of the angle measurement is again indicated by setting the INT output 2118 and a corresponding flag in the status register.

Due to the measurement principle of the AS5055 position sensor 2102, only a single angle measurement is performed in very short time (˜600 μs) after each power-up sequence. As soon as the measurement of one angle is completed, the AS5055 position sensor 2102 suspends to power-down state. An on-chip filtering of the angle value by digital averaging is not implemented, as this would require more than one angle measurement and, consequently, a longer power-up time that is not desired in low-power applications. The angle jitter can be reduced by averaging of several angle samples in the controller 2104. For example, an averaging of four samples reduces the jitter by 6 dB (50%).

FIG. 19 illustrates a logic flow diagram of a process 2200 for monitoring a motor current of a surgical instrument 100, according to one aspect of the present disclosure. In the following description of the process 2200, reference should also be made to FIGS. 16-18, which depict various sensor assemblies utilized by the process 2200, and FIGS. 20-21, which depict various firing strokes of the clamping member 550 executed according to the process 2200. The presently described process 2200 can be executed by a controller, which includes the control circuit depicted in FIGS. 16-17, the microcontroller 2104 of FIG. 18, or another control circuit and/or processor that is executing logic and/or instructions stored in a memory of the surgical instrument 100. The process 2200 begins to be executed when the clamping and cutting/stapling operations of the end effector 500 are initiated 2202.

Accordingly, the process 2200 executed by the controller advances 2204 the clamping member 550 from a first or proximal position by energizing the motor 2010 to which the clamping member 550 is operably connected. The advancement of the clamping member 550 between a first or proximal position and a second or distal position can be referred to as a stroke or a firing stroke. During the course of a full stroke of the clamping member 550, the clamping member 550 will clamp the end effector 500 and then cut and/or staple tissue held thereby. The stroke of the clamping member 550 can be represented, for example, as a graph where the x-axis corresponds to the distance or time over which the clamping member 550 has advanced, as depicted in FIGS. 20-21. The actions effectuated by the clamping member 550 can correspond to positions or zones defined within the stroke of the clamping member 550. For example, there can be a position in the stroke where the clamping member 550 has closed the end effector 500 and is thereafter cutting and/or stapling tissue. As another example, there can be a position in the stroke of the clamping member 550 where the clamping member 550 is no longer ejecting staples or cutting tissue. The controller can also take various actions according to the position of the clamping member 550. For example, there can be a position where the speed at which the clamping member 550 is driven is controlled or changed by a controller. These positions or zones can refer to actual physical positions at which the clamping member is located or relative positions within the stroke of the clamping member. The positions or zones can alternatively be represented as times in the stroke of the clamping member 550, as depicted in FIG. 20.

As the clamping member 550 is advanced 2204, the controller detects 2206 the motor current via, for example, the current sensor 2018. The controller then determines 2208 whether the clamping member 550 is at the closure end position. In one example, the controller can determine 2208 whether the clamping member is at the closure end position via the position sensor 2102. The closure end position corresponds to the location in the firing stroke of the clamping member 550 after the clamping member 550 has closed the end effector 500 and is thereafter cutting tissue and/or firing staples as the clamping member 550 continues to advance distally. In some aspects, the controller can retrieve the closure end position from a memory and then compare the stored closure end position to the detected position of the clamping member 550 to determine if the detected position matches or exceeds the stored closure end position. In other aspects, the controller can determine the closure end position by, for example, monitoring for a peak in the motor current. If the clamping member 550 is not at the closure end position, the process 2200 proceeds along the NO branch and the controller continues causing the motor 2010 to advance 2204 the clamping member 550. The process 2200 continues this loop until the clamping member 550 is located at the closure end position.

If the controller determines 2208 that the clamping member 550 is located at or beyond the closure end position, the process 2200 proceeds along the YES branch and the controller selects 2210 the target firing speed at which the clamping member 550 is to be driven by the motor 2010 according to the value of the motor current at the closure end position. The level of motor current required to close the end effector 500 can be indicative of various properties of the clamped tissue. For example, the value of the motor current at the closure end position can correspond to the thickness of the clamped tissue because the force exerted by the clamping member 550 to clamp tissue is proportional to the thickness of the tissue. As the force exerted by the clamping member 550 or the torque exerted by the motor 2010 is proportional to the current drawn by the motor 2010, the level of the motor current at the closure end position thus corresponds to the thickness of the clamped tissue. It can be desirable to set the target firing speed at which the clamping member 550 is driven according to the thickness of the clamped tissue because advancing the clamping member 550 too quickly through thick tissue can cause improper staple formation and increase the strain on the motor 2010. As another example, the level of motor current can also correspond to the anatomical type of the clamped tissue (e.g., lung tissue, gastrointestinal tissue, or cardiac tissue) because the physical resistance exerted on the cutting surface 554 driven by the clamping member 550 can vary for different tissue types. In some aspects, the controller can compare the sensed value of the motor current at the closure end position to a range of motor current values and then determine whether the sensed motor current has exceeded one or more thresholds or falls within one or more zones of the range. The controller can then select 2210 the target firing speed for the clamping member 550 as a particular value or set a tolerance threshold for the target firing speed including a range of values, which correspond to where the sensed motor current lies within the range.

After selecting 2210 the target firing speed, the controller then causes the clamping member 550 to advance 2212 at an initial speed. The initial speed and the length of time or distance over which the clamping member 550 is advanced at the initial speed can be set values that are retrieved by the controller from a memory or calculated values that are determined by the controller as a function of the tissue thickness. In some aspects, the controller lacks this step of the process 2200 and instead simply proceeds to advance the clamping member 550 at the determined target speed. The initial speed can be a value that is less than the target firing speed. In other words, the controller can cause the motor 2010 to initially advance the clamping member 550 at a lower speed in a first zone or portion of the firing strike relative to a subsequent portion or zone of the firing stroke. In some aspects, the value of the initial speed can be zero or nearly zero. It can be desirable to advance 2212 the clamping member 550 at a lower speed initially in order to allow the fluid to drain from the tissue clamped at the end effector 500. Fluid drains from clamped tissue due to the mechanical forces exerted on the tissue by the end effector 500. In one aspect, the length of time or distance that the clamping member 550 is advanced at the initial speed can vary according to the thickness of the clamped tissue.

During the portion of the firing stroke of the clamping member 550 directly following the closure end position, the controller further determines 2214 whether the motor current exceeds a maximum or lockout threshold. The controller can retrieve the lockout threshold from a memory. The sensed motor current exceeding the lockout threshold indicates that the clamping member 550 is not being advanced distally from the closure end position. The clamping member 550 can be prevented from advancing distally in the portion of its firing stroke immediately following the closure end position for a variety of reasons, such as if the end effector 500 lacks a staple cartridge assembly 700. If the motor current exceeds the lockout threshold, the process 2200 proceeds along the YES branch and stops 2216 in order to reduce strain on the motor 2010. The controller can thereafter cause the surgical instrument 100 to display an alert to the operator or take other such actions.

If the motor current does not exceed the lockout threshold, the process 2200 proceeds along the NO branch the controller then causes the clamping member 550 to advance 2218 at an increasing rate of speed until the speed reaches the target speed value or is within the target speed range (which is a function of the tissue thickness). In some aspects, the rate at which the controller causes the motor 2010 to drive the clamping member 550 to increase the speed of the clamping member 550 is a set or predetermined rate. In other aspects, the rate at which the speed of the clamping member 550 is increased is a function of one or more parameters, such as the tissue thickness. In other words, the controller could be configured to cause the speed of the clamping member 550 to increase more slowly for thicker tissue or increase more quickly for thinner tissue.

As the clamping member 550 is advanced distally (i.e., fired), the controller detects 2220 the motor current. The controller accordingly determines 2222 whether the sensed motor current exceeds a threshold value. In one example, the threshold value can be retrieved by the controller from a memory for comparison to the detected 2220 motor current. This threshold can be the same or different than the lockout threshold described above. Furthermore, the threshold can correspond to the tissue thickness, for example. In some aspects, if the controller determines 2222 that the motor current has exceeded the determined threshold, then the process 2200 proceeds along the YES branch and the controller decreases 2224 the firing speed of the clamping member 550. In other aspects, if the controller determines 2222 that the motor current has exceeded the determined threshold, then the process 2200 proceeds along the YES branch and the controller pauses 2224 the clamping member 550 at its current position in its firing stroke. Decreasing the firing speed of or pausing 2224 the clamping member 550 reduces the torque experienced by the motor 2010 (to zero, in the case of pausing the clamping member 550). After a particular length of time or after the clamping member 550 had advanced a particular distance (in the case where the clamping member 550 is slowed, not paused), the process 2200 loops back and the controller again causes the clamping member 550 to advance 2218. The elapsed time or distance before which the controller begins causing the clamping member 550 to increase in speed can be a set value or can be a function of a tissue parameter (e.g., the tissue thickness).

If the controller determines 2222 that the clamping member 550 has not exceeded a threshold, the process 2200 proceeds along the NO branch and the controller then determines 2226 whether the clamping member 550 is located at the firing end position. The firing end position corresponds to the distal point reached by the clamping member 550 in its firing stroke to cut tissue and/or fire staples from the end effector 500. If the clamping member 550 has not reached the firing end position, the process 2200 proceeds along the NO branch and loops back. The controller then continues to advance 2218 the clamping member 550 (and increase its speed, as appropriate) and detects 2220 the motor current during the course of the firing stroke to determine 2222 whether the motor current exceeds the threshold. The controller continues this loop until it determines 2226 that the clamping member 550 is located at the firing end position. If the controller determines 2226 that the clamping member 550 is located at the firing end position, the process 2200 proceeds along the YES branch and then stops 2228.

To provide further explanation regarding the function(s) described above that the controller is configured to execute, the process 2200 will be discussed in terms of several example firing strokes depicted in FIGS. 20-21. FIG. 20 illustrates a first graph 2300 and a second graph 2302, each of which depict a first firing stroke 2304 and a second firing stroke 2306 of the clamping member 550. The first graph 2300 depicts motor current 2303 versus time 2301 and the second graph 2302 depicts clamping member speed 2305 versus time 2301 for the example firing strokes 2304, 2306 of the clamping member 550. The time 2301 axis is delineated into a “CLOSURE” zone, a “CUTTING/STAPLING” zone, and a “STOP” zone, which indicates the action(s) that the clamping member 550 is effectuating in each respective portion of its firing stroke. In combination, the first graph 2300 and the second graph 2302 illustrate the relationship between motor current 2303 and clamping member speed 2305 for different firing strokes 2304, 2306 and the resulting actions taken by a controller executing the process 2200 depicted in FIG. 19.

As discussed above in connection with FIG. 19, the controller executing the process 2200 can be configured to select 2210 the firing speed at which the clamping member 550 is to be driven according to the motor current at the closure end position 2308. In other words, the controller is configured to select 2210 a firing speed of the clamping member 550 that is appropriate for or that otherwise corresponds to the thickness of the clamped tissue, as indicated by the motor current at the closure end position 2308. In one aspect, the controller selects the firing speed of the clamping member 550 according to where the sensed motor current at the closure end position 2308 falls within a range of values. In some aspects, this can be expressed as whether the motor current at the closure end position 2308 has surpassed one or more thresholds in a range of motor current values. In other aspects, this can be expressed as whether the motor current at the closure end position 2308 falls within a particular zone or zones in a range of motor current values.

In the depicted aspect, there are a first threshold T₁, a second threshold T₂, and a third threshold T₃, which can demarcate zones corresponding to thin tissue, medium tissue, and thick tissue, respectively. In other words, if the motor current at the closure end position 2308 is below T₁, then the tissue can be considered to be thin because relatively little torque was exerted by the motor 2010 to clamp the end effector 500 on the tissue. Accordingly, if the motor current at the closure end position 2308 has exceeded T₁, but is below T₂, then the tissue can be considered to be of medium, normal, or expected thickness. Accordingly, if the motor current at the closure end position 2308 has exceeded T₂, but is below T₃, then the tissue can be considered to thick because the motor 2010 was required to exert a high degree of torque to clamp the tissue. If the motor current at the closure end position 2308 exceed T₃, then the tissue can be considered to be too thick to cut and staple or may have been clamped improperly. In that case, the process 2200 can display a warning to the operator and/or lockout the surgical instrument 100 from advancing the clamping member 550 further. The depiction of three thresholds T₁, T₂, T₃ is simply illustrative and the process 2200 can incorporate any number of thresholds, however. The speed at which the clamping member 550 is to be driven can be selected by the process 2200 executed by the controller to correspond to the relative tissue thickness, which is indicated by the motor current at the closure end position 2308. In the depicted aspect, there are a first speed zone S₁ that is selected if the motor current does not exceed T₁, a second speed zone S₂ that is selected if the motor current falls between T₁ and T₂, and a third speed zone S₃ that is selected if the motor current falls between T₂ and T₃. The first speed zone S₁ to the third speed zone S₃ correspond to increasingly slower speeds. It can be desirable to drive the clamping member 550 at a faster rate through thinner tissue because thin tissue provides little resistance to proper staple formation and thus the operation can be completed more quickly without sacrificing staple quality. Conversely, it can be desirable to drive the clamping member 550 at a slower rate through thicker tissue because staples may not be formed properly in thicker tissue if the sled 712 (FIG. 10) is driven too quickly by the clamping member 550. Driving the sled 712 at a slower rate thus ensures that the staples fully pierce the tissue and are fully formed against the anvil plate 620 (FIG. 10).

The first firing stroke 2304 and the second firing stroke 2306 are examples where the controller determines 2222 that the motor current exceeds a threshold during the course of the clamping member firing stroke and then pauses 2224 the clamping member 550. For example, in the first firing stroke 2304 the closure motor current 2312 at the closure end position 2308 has exceed the second threshold T₂; therefore, the controller selects the slowest speed zone S₃ as the target speed at which the clamping member 550 is to be driven during the cutting/stapling phase of the firing stroke. In the second firing stroke 2306 the closure motor current 2319 at the closure end position 2308 has exceed the first threshold T₁; therefore, the controller selects the medium speed zone S₂ as the target speed at which the clamping member 550 is to be driven during the cutting/stapling phase of the firing stroke. The speed zones S₁, S₂, S₃ set the upper and lower tolerance thresholds for the speed at which the clamping member 550 is driven by the motor 2010. If the speed of the clamping member 550 exceeds the upper and lower limits of the speed zone S₁, S₂, S₃ selected by the controller, then the controller can be configured to take various actions, such as controlling the motor 2010 to increase or decrease the speed at which the clamping member 550 is driven or adjusting the electrical energy supplied to the motor 2010. In other words, the speed zones S₁, S₂, S₃ represent ranges of acceptable speeds in which the speed at which the clamping member 550 is actually translated can vary without causing the controller to take corrective action. It should be appreciated that although the target speed zones S₁, S₂, S₃ are depicted as ranges in the second graph 2302, they could alternatively be discrete values. In general, it can be desirable to set tolerance ranges for the speed at which the clamping member 550 is advancing because the speed will naturally vary during a firing stroke because tissue is not uniform in thickness, the clamping member 550 tends to slow as the sled 712 ejects staples (which are spaced from each other), and the tissue cutting surface 554 (FIG. 10) may be advancing through different types of tissue with different physical properties.

Continuing the description of the first firing stroke 2304, after the closure end position 2308 the controller causes the speed at which the clamping member 550 is advanced to drop from the closure speed 2332 to an initial speed 2333, which may be lower than the selected target speed (and in some cases is zero). The initial speed 2333 corresponds to a low initial motor current 2313. The controller then gradually increases the speed at which the clamping member 550 is driven to a target speed 2334 that is within the target speed range S₃ previously selected by the controller. As the clamping member speed increases, the motor current likewise increases 2314. If the clamping member 550 does not encounter any abnormal resistance from the tissue as the tissue cutting surface 554 is driven therethrough, the clamping member speed will thus be maintained within the target speed range S₃ through the firing stroke until the stop position 2310. However, in this example, the speed instead begins decreasing thereafter. As the speed decreases, the motor current increases until it peaks 2315 and reaches the maximum threshold T₃. The clamping member speed dropping while the motor current is simultaneously increasing indicates that the tissue cutting surface 554 driven by the clamping member 550 is encountering thicker than expected tissue or there is otherwise an error that is causing the torque on the motor 2010 to increase unexpectedly. When unexpectedly thick tissue is encountered, the torque on the motor 2010 can increase while the clamping member speed is, at best, maintained or, in this case, falls. When the motor current meets or exceeds the maximum threshold T₃ (at peak 2315), the controller reduces or cuts 2316 the current to the motor 2010, which cause the clamping member speed to drop 2335 to a lower speed or, in some aspects, to zero (i.e., the clamping member 550 is paused). After a period of time, the controller re-energizes the motor 2010 and gradually increases 2317 the motor current in order to cause the speed at which the clamping member 550 is driven to gradually increase to a target speed 2336 within the target speed range S₃. As long as the motor current does not re-exceed the maximum threshold T₃, the clamping member 550 continues to advance until it reaches the stop position 2310. At that point, the controller causes the motor current to drop 2318 to zero and the clamping member speed likewise drops 2337 to zero as the clamping member slows to a stop due to the motor 2010 being de-energized.

A similar series of events described above with respect to the first firing stroke 2304 occurs with respect to the second firing stroke 2306, except that the controller selects the target speed range as S₂ because the closure motor current 2319 only exceeded the first threshold T₁ at the closure end position 2308. As with the first firing stroke 2304, after the closure end position 2308 the controller causes the speed at which the clamping member 550 is advanced to drop from the closure speed 2326 to an initial speed 2327. The controller then gradually increases the speed at which the clamping member 550 is driven to a target speed 2328 that is within the target speed range S₂ previously selected by the controller. As the clamping member speed increases, the motor current likewise increases 2321. As with the first firing stroke 3406, the speed begins decreasing and the motor current increases until it peaks 2322 and reaches the maximum threshold T₃. As the motor current meets or exceeds the maximum threshold T₃ (at peak 2322), the controller reduces or cuts 2323 the current to the motor 2010, which cause the clamping member speed to drop 2329 to a lower speed or, in some aspects, to zero (i.e., the clamping member 550 is paused). After a period of time, the controller re-energizes the motor 2010 and gradually increases 2324 the motor current to increase the clamping member speed a target speed 2330 within the target speed range S₂. The time delay prior to the controller re-energizing the motor can vary for different conditions encountered during the firing stroke. As can be noted from either the first graph 2300 or the second graph 2302, the length of time that the current is cut 2316 in the first firing stroke 2304 is greater than the length of time that the current is cut 2323 in the second firing stroke 2306. In some aspects, the length of the pause (or the length of time at which the clamping member 550 is driven at a lower or initial speed) can be a function of the tissue thickness. For example, the controller can pause the advancement of the clamping member 550 longer for thicker tissue. The controller continues to advance the clamping member 550 until it reaches the stop position 2338. At that point, the controller causes the motor current to drop 2325 to zero and the clamping member speed likewise drops 2331 to zero as the clamping member slows to a stop due to the motor 2010 being de-energized. As can further be noted, the stop position 2338, 2310 can vary. In some aspects, the location of the stop position 2338, 2310 can vary according to the length of the cartridge body 702 present into the end effector 500. In other aspects, the location of the stop position 2338, 2310 can be set by the operator of the surgical instrument 100 to a shorter (i.e., more proximal) position than the maximum stop position.

FIG. 21 illustrates a third graph 2400 and a fourth graph 2402, each of which depict a third firing stroke 2404, a fourth firing stroke 2406, and a fifth firing stroke 2408 of the clamping member 550. The third graph 2400 depicts motor current 2403 versus clamping member displacement distance 2401 and the fourth graph 2402 depicts clamping member speed 2405 versus displacement distance 2401 for the example firing strokes 2404, 2406, 2408 of the clamping member 550. The displacement distance 2401 axis is delineated into a “CLOSURE” zone, a “CUTTING/STAPLING” zone, and a “STOP” zone, which indicates the action(s) that the clamping member 550 is driving in each respective portion of its firing stroke. In combination, the third graph 2400 and the fourth graph 2402 illustrate the relationship between motor current 2403 and clamping member speed 2405 for different firing strokes 2404, 2406, 2408 and the resulting actions taken by a controller executing the process 2200 depicted in FIG. 19.

As discussed above in connection with FIG. 19, the controller executing the process 2200 can be configured to select 2210 the firing speed at which the clamping member 550 is to be driven according to the motor current at the closure end position 2410. In other words, the controller is configured to select 2210 a firing speed for the clamping member 550 that is appropriate for or that otherwise corresponds to the thickness of the clamped tissue, as indicated by the motor current at the closure end position 2410. In one aspect, the controller selects the firing speed of the clamping member 550 according to where the sensed motor current at the closure end position 2410 falls within a range of values. In some aspects, this can be expressed as whether the motor current at the closure end position 2410 has surpassed one or more thresholds in a range of motor current values. In other aspects, this can be expressed as whether the motor current at the closure end position 2410 falls within a particular zone or zones in a range of motor current values. In the depicted aspect, the motor current 2403 includes a first zone i₁, a second zone i₂, and a third zone i₃. The zones may or may not be contiguous with each other. The depiction of three zones i₁, i₂, i₃ along the axis of the motor current 2403 is simply illustrative and the process 2200 can incorporate any number of thresholds, however.

As also discussed above in connection with FIG. 19, the process 2200 executed by the controller can be configured to determine 2214 whether the motor current exceeds a lockout threshold 2415. The third firing stroke 2404 represents an example firing stroke wherein the controller determines 2214 that the lockout threshold 2415 is exceeded. In the third firing stroke 2404, the motor current spikes 2414 in the portion of the firing stroke immediately following the closure end position 2410, reaching or exceeding the lockout threshold 2415, as the clamping member speed sharply drops 2416 to zero. In other words, the motor current increases sharply with minimal or no corresponding movement of the clamping member 550. When the motor current reaches the lockout threshold 2415, the process 2200 executed by the controller stops 2216 and the controller can display a warning to the operator and/or lockout the surgical instrument 100 from firing the clamping member 550. In one example, the spike 2414 in the motor current exhibited by the third firing stroke 2404 directly after the closure end position 2410 can be indicative of a cartridge 702 not being present or being improperly loaded in the end effector 500.

The fourth firing stroke 2406 is an example where controller determines 2222 that the motor current exceeds a threshold during the course of the clamping member stroke and then decreases 2224 the speed of the clamping member 550. In the fourth firing stroke 2406, the closure motor current 2418 falls within the i₂ zone; therefore, the controller selects S₂ as the target speed range 2436. After the closure end position 2410, the controller causes the clamping member speed to decrease from the closure speed 2432 to an initial speed 2434. The controller then causes the displacement member speed to increase from the initial speed 2434 to a target speed 2436 in the selected speed range S₂. It should be noted that the initial speed 2434 can be a set value or a range of values. The motor current correspondingly increases 2420 as the displacement member speed increases. As the clamping member 550 continues advancing in the fourth firing stroke 2406, the clamping member 550 hits a point where the motor current sharply increases 2422 such that it exceeds a threshold demarcated by the upper boundary of the i₂ zone. The sharp increase 2422 in the motor current is indicative of the cutting surface 554 being driven through an unexpectedly thick portion of the clamped tissue. In this example, there are multiple thresholds (demarcated by the boundaries of the current zones i₁, i₂, i₃) that the controller compares the sensed motor current against to determine 2222 whether to decrease 2224 the displacement member speed or pause the clamping member 550. This is in contrast to the first firing stroke 2304 and the second firing stroke 2306 where the controller only took action (i.e., paused the clamping member 550 in the particular examples) when the motor current reached or exceeded a singular maximum threshold (T₃). When the motor current exceeds the threshold, the controller decreases 2438 the clamping member speed from the original speed range S₂ to the lower speed range S₃. The controller then causes the motor 2010 to advance the clamping member 550 at the lower speed 2440. As the clamping member 550 advances at the lower speed range S₃, the motor current continues 2424 in the higher current range i₃ until it sharply decreases 2426 past the lower boundary of the i₃ current zone. The sharp decrease 2426 in the motor current is indicative of the cutting surface 554 being driven through a thinner portion of the clamped tissue because less current is required to advance the clamping member 550 at the target speed. When the motor current reaches or exceeds the threshold represented by this lower boundary, the controller then causes the motor 2010 to increase 2442 the clamping member speed from the lower speed range S₃ back to the original speed range S₂. Through the remaining portion of the fourth firing stroke 2406, the displacement member speed continues 2444 within the target speed range S₂ (with the motor current likewise continuing 2428 with its respective range i₂) until the clamping member 550 reaches the firing end position 2412. When the clamping member 550 reaches the firing end position 2412, the controller cuts 2430 the motor current and the clamping member speed correspondingly drops 2446 to zero as the motor 2010 is de-energized.

The fifth firing stroke 2408 represents a firing stroke wherein the clamping member 550 is driven through clamped tissue lacking any significant variations in thickness. In the fifth firing stroke 2408, the closure motor current 2448 falls within the i₁ zone; therefore, the controller selects S₁ as the target speed range 2458. After the closure end position 2410, the controller causes the clamping member speed to decrease from the closure speed 2454 to an initial speed 2456. The controller then causes the displacement member speed to increase from the initial speed 2456 to a target speed 2458 in the selected speed range S₃. In the present example, the clamping member 550 maintains its speed within the target speed 2458 for the entire length of the firing stroke. The motor current is likewise maintained 2450 within the boundaries of the current zone i₁. In other words, the clamping member 550 does not encounter any portions of tissue that is appreciably thicker or thinner relative to the expected tissue thickness (i.e., the tissue thickness indicated by the closure motor current 2418) as the clamping member 550 advances from the closure end position 2410 to the firing end position 2412. When the clamping member 550 reaches the firing end position 2412, the controller cuts 2452 the motor current, which causes the clamping member speed to drop 2460 to zero as the motor 2010 is de-energized.

FIG. 22 illustrates a diagram of an end effector 10000 including a gap sensor 10006 and a cartridge identity sensor 10010, according to one aspect of the present disclosure. The gap sensor 10006 is configured to sense the gap or distance between the first jaw member 10004 (i.e., the anvil assembly 610) and the second jaw member 10006 (i.e., the cartridge assembly 700) by sensing the relative position of a magnet 10008. The position sensor 10006 can include a Hall effect sensor, among other sensors configured to detect the relative distance between components. In one aspect depicted in FIG. 23, the position sensor 10006 comprises a Hall element 10100, an amplifier 10102, and a power source 10104. The Hall element comprises a first input terminal 10108A and a second input terminal 10108B. The first and second input terminals 10108A, 10108B are configured to receive a constant input current from the power source 10104. When no magnetic field is present, the input current enters the first input terminal 10108A and exits the second input terminal 10108B with no loss of voltage potential to either side of the Hall element 10100. As a magnetic field is applied to the Hall element 10100, such as, for example, by magnet 10008, a voltage potential is formed at the sides of the Hall element 10100 due to the deflection of electrons flowing through the Hall element 10100. A first output terminal 10108C and a second output terminal 10108D are located at opposite sides of the Hall element 10100. The first and second output terminals 10108C, 10108D provide the voltage potential caused by the magnetic field to the amplifier 10102. The amplifier 10102 amplifies the voltage potential experienced by the Hall element 10100 and outputs the amplified voltage to an output terminal 10106. Therefore, the output of the position sensor 10006 corresponds to the relative distance of the magnet 10008 to the Hall element 10100. Detecting the distance between the jaw members 10006, 10008 can be beneficial because this distance corresponds to the thickness of the grasped tissue when the end effector 10000 is clamped. Therefore, sensing the distance between the jaw member 10006, 10008 can be used in lieu of, or in addition to, determining the tissue thickness from the motor current to clamp the end effector 10000, as described above.

Referring back to FIG. 22, the cartridge identity sensor 10010 is configured to sense the type or identity of a cartridge 702 present in the end effector 10000. In one aspect where the end effector 10000 is a MULU with replaceable cartridges 702, the cartridge identity sensor 10010 includes a receiver that is configured to receive a signal (e.g., a RF signal) transmitted from the cartridge 702. In another aspect where the end effector 10000 is a MULU, the cartridge identity sensor 10010 includes an electrical contact that is configured to contact a corresponding electrical contact of the cartridge 702 when the cartridge 702 is inserted into the end effector 10000. Upon the cartridge 702 being inserted, the cartridge 702 transmits a signal through the electrically connected electrical contacts, which is received by a controller of the surgical instrument 100 to identity the cartridge 702.

In another aspect where the end effector 10000 is a SULU, the cartridge identity sensor 10010 is configured to detect when the end effector 10000 is mated to the adapter 200. In this aspect depicted in FIGS. 24-25, the terminal end 10206 of the adapter 200 includes one or more electrical contacts 10200, which each include a bent portion 10202. The end effector 500 further includes a memory disposed within or on the end effector housing 10201. The memory includes a memory chip and one or more electrical contacts 10204 electrically connected to the memory chip. The memory chip is configured to store one or more parameters relating to the end effector 500. The parameters can include a serial number of the end effector 500, a type of the end effector 500 and/or the cartridge 702 therein, a size of end effector 500 and/or the cartridge 702 therein, a staple size, information identifying whether the end effector 500 has been fired, a length of the end effector 500 and/or the cartridge 702 therein, maximum number of uses of the end effector 500, and combinations thereof. When the end effector 500 is mated to the adapter 200, the end effector electrical contacts 10204 engaged the adapter electrical contacts 10200. The memory chip is configured to communicate the presence of the end effector 500 and one or more of the parameters of the end effector 500 described herein, via electrical contacts 10200, 100204, upon engagement of the end effector 500 with the adapter 200.

FIG. 26 illustrates a logic flow diagram of a process 10300 for selecting an initial speed at which to fire the clamping member 550, according to one aspect of the present disclosure. In the following description of the process 10300, reference should also be made to FIGS. 22-25, which depict various sensor assemblies utilized by the process 10300, and FIG. 27, which depicts various firing strokes of the clamping member 550 executed according to the process 10300. The presently described process 10300 can be executed by a controller, which includes the control circuit depicted in FIGS. 16-17, the microcontroller 2104 of FIG. 18, or another control circuit and/or processor that is executing logic and/or instructions stored in a memory of the surgical instrument 100. The process 10300 begins to be executed when the clamping and cutting/stapling operations of the end effector 500 are initiated 10302.

Accordingly, the process 10300 executed by the controller first advances 10304 the clamping member 550 by energizing the motor 2010 to which the clamping member 550 is operably connected. The controller then determines 10306 whether the clamping member 550 is at the closure end position. In one example, the controller can determine 10306 whether the clamping member 550 is at the closure end position via the position sensor 2102 (FIG. 18). The closure end position corresponds to the location in the firing stroke of the clamping member 550 after the clamping member 550 has closed the end effector 500 and is thereafter cutting tissue and/or firing staples. In some aspects, the controller can retrieve the closure end position from a memory and then compare the known closure end position to the sensed position of the clamping member 550. In other aspects, the controller can determine the closure end position by monitoring for a peak in the motor current. If the clamping member 550 is not at the closure end position, the process 10300 proceeds along the NO branch and the controller continues causing the motor 2010 to advance 10304 the clamping member 550. The process 2200 continues this loop until the clamping member 550 is located at or beyond the closure end position.

If the controller determines 10306 that the clamping member 550 is located at or beyond the closure end position in its firing stroke, the process 10300 proceeds along the YES branch and then determines 10308 the gap distance between the anvil assembly 610 and the cartridge assembly 700. In one example, the controller determines 10308 the gap distance via the gap sensor 10006. The controller then determines 10310 the type or identity of the cartridge 702 and/or the end effector 500. In one example, the controller determines 10310 the type or identity of the cartridge 702 via the cartridge identity sensor 10100. The cartridge then determines 10312 whether the gap distance is acceptable for the sensed cartridge type. Different types of cartridges 702 have different acceptable tolerance ranges; therefore, a gap distance between the anvil assembly 610 and the cartridge assembly 700 that is suitable (i.e., within operational tolerances) for one type of cartridge 702 may not be suitable for another type of cartridge 702. If the controller determines that the gap distance is not suitable for the given cartridge type, the process 10300 proceeds along the NO branch and stops 10314. In that case, the process 10300 can display a warning to the operator and/or lockout the surgical instrument 100 from firing the clamping member 550.

If the controller determines that the gap distance is suitable for the given cartridge type, the process 10300 proceeds along the YES branch and next determines 10316 the target firing speed for the clamping member 550 according to the sensed gap distance and the sensed cartridge type. In one aspect, the controller can select a target firing speed according to whether the sensed gap distance exceeds one or more thresholds or falls within one or more zones within a range of gap distances that are particular to a given cartridge type. In other words, different cartridge types may have different tolerance ranges for the speeds at which the clamping member 550 can be advanced for different thicknesses of the clamped tissue. Across cartridge types, the controller can be configured to generally select slower firing speeds for thicker tissue and faster firing speeds for thinner tissue; however, whether a given thickness of tissue is considered to be relatively thick or relatively thin will vary according to the cartridge type. After determining 10316 the appropriate target firing speed, the process 10300 stops 10318.

To provide further explanation regarding the function(s) described above that the controller is configured to execute, the process 10300 will be discussed in terms of several example firing strokes depicted in FIG. 27. FIG. 27 illustrates a graph 10400 that depicts several firing strokes 10406, 10408, 10410, 10412, 10414, 10416, 10418 of the clamping member 550 corresponding to different cartridge types. In the graph 10400, the first firing stroke 10406, the second firing stroke 10408, the fifth firing stroke 10414, and the seventh firing stroke 10418 correspond to a first cartridge type; the third firing stroke 10410 and the sixth firing stroke 10416 correspond to a second cartridge type; and the fourth firing stroke 10412 corresponds to a third cartridge type. The graph 10400 depicts the gap distance 10404 of the end effector 500 versus the displacement distance 10402 of the clamping member 550. The resulting actions taken by a controller executing the process 10300 (i.e., determining 10316 the firing speed) depends upon gap distance 10404 at the closure end position 10420 for the cartridge type of each firing stroke. The graph 10400 also depicts a variety of thresholds x₁ . . . x₆ along the gap distance 10404 axis that delineate zones therebetween. The sequentially increasing thresholds x₁ . . . x₆ can correspond to increasingly larger values of the gap distance 10404. Each cartridge type does not necessarily utilize all of the depicted thresholds x₁ . . . x₆ and different cartridge types can use the same or different thresholds x₁ . . . x₆ and/or zones, as will be discussed below. Furthermore, although six thresholds x₁ . . . x₆ are depicted, the process 10300 executed by the controller can utilize any number of thresholds and/or zones in practice.

For the first cartridge type, the thresholds x₆, x₅, and x₃ define the zones that determine the firing speed selected by the controller. For example, at the closure end position 10420 the first firing stroke 10406 is located at a position 10407 exceeding x₆. Exceeding the x₆ threshold corresponds to the clamped tissue being too thick to cut and staple for the given cartridge type or having been clamped improperly. In this case, the controller can display a warning to the operator and/or lockout the surgical instrument 100 from firing the clamping member 550. The second firing stroke 10408 is located at a position 10409 in a zone between x₆ and x₅ at the closure end position 10420, which corresponds to a large gap or thick tissue for the given cartridge type. Therefore, the controller can select a slower firing speed for the clamping member 550. The fifth firing stroke 10414 is located at a position 10415 in a zone between x₅ and x₃ at the closure end position 10420, which corresponds to a medium gap or medium, normal, or expected tissue thickness for the given cartridge type. Therefore, the controller can select a medium or normal firing speed for the clamping member 550. The seventh firing stroke 10418 is located at a position 10419 in a zone below x₃ at the closure end position 10420, which corresponds to a small gap or thin tissue for the given cartridge type. Therefore, the controller can select a fast firing speed for the clamping member 550.

The relevant thresholds can vary for different cartridge types. For the second cartridge type, the x₄ threshold delineates zones defining a fast firing speed and a normal firing speed. For example, the third firing stroke 10410 is located at a position 10411 in a zone above x₄ at the closure end position 10420, which corresponds to a medium gap or a medium, normal, or expected tissue thickness for the given cartridge type. Therefore, the controller can select a medium or normal firing speed for the clamping member 550. The sixth firing stroke 10416 is located at a position 10417 in a zone below x₄ at the closure end position 10420, which corresponds to a small gap or thin tissue for the given cartridge type. Therefore, the controller can select a fast firing speed for the clamping member 550.

The relevant thresholds can also be shared between different cartridge types. For the third cartridge type, the x₄ threshold delineates zones defining a fast firing speed and a normal firing speed (as with the second cartridge type of the third firing stroke 10410 and the sixth firing stroke 10416). For example, the fourth firing stroke 10412 is located at a position 10413 in a zone below x₄ at the closure end position 10420, which corresponds to a small gap or thin tissue for the given cartridge type. Therefore, the controller will select a fast firing speed for the clamping member 550.

In sum, the process 10300 executed by the controller can select the appropriate firing speed for the clamping member 550 during the cutting/stapling portion of its firing stroke according to where the sensed gap distance between the anvil assembly 610 and the cartridge assembly 700 falls relative to various tolerance ranges, which may be unique to each cartridge type. The process 10300 thus allows the controller to customize the speed at which the clamping member 550 is fired to cut and/or staple tissue according to the thickness of the clamped tissue and the cartridge type.

Although various aspects have been described herein, many modifications and variations to those aspects may be implemented. For example, different types of end effectors may be employed. Also, where materials are disclosed for certain components, other materials may be used. The foregoing description and following claims are intended to cover all such modification and variations.

Any patent, publication, or other disclosure material, in whole or in part, that is said to be incorporated by reference herein is incorporated herein only to the extent that the incorporated materials does not conflict with existing definitions, statements, or other disclosure material set forth in this disclosure. As such, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

Various aspects of the subject matter described herein are set out in the following numbered examples:

EXAMPLE 1

A surgical instrument comprising a motor that includes a control circuit coupled thereto and configured to detect whether an end effector that is connectable to the surgical instrument is in a closed position. In at least one example, the end effector is configured to receive a cartridge that supports a plurality of staples. The control circuit is also configured to detect a position of a clamping member that is drivable by the motor between a first position and a second position. The clamping member is configured to transition the end effector to the closed position as the clamping member moves from the first position to the second position and deploy the plurality of staples from the cartridge after the end effector is in the closed position as the clamping member moves to the second position. The control circuit is further configured to cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position and cause the motor to drive the clamping member at a second rate in a second zone between the first position and the second position. In at least one example, the first rate is less than the second rate.

EXAMPLE 2

The surgical instrument of Example 1, wherein the first zone is located proximally relative to the second zone.

EXAMPLE 3

The surgical instrument of Example 1, wherein the first zone is located prior to the second zone.

EXAMPLE 4

The surgical instrument of Example 1, 2 or 3, wherein a length of the first zone corresponds to a thickness of a tissue grasped at the end effector.

EXAMPLE 5

The surgical instrument of Example 3, wherein the surgical instrument comprises a sensor that is configured to detect a gap between the jaw members of the end effector. The gap corresponds to the thickness of the tissue.

EXAMPLE 6

The surgical instrument of Examples 4 or 5, wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue.

EXAMPLE 7

A surgical instrument comprising a motor that includes a control circuit coupled thereto wherein the control circuit is configured to detect whether an end effector that is connectable to the surgical instrument is in a closed position. In at least one example, the end effector is configured to receive a cartridge that supports a plurality of staples. The control circuit is further configured to detect a position of a clamping member that is drivable by the motor between a first position, a second position, and a third position. The clamping member is configured to transition the end effector to the closed position as the clamping member moves from the first position to the second position. The clamping member is further configured to deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position. The control circuit is further configured to cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position and cause the motor to drive the clamping member at a second rate in a second zone between the second position and the third position. In at least one example, the first rate is less than the second rate.

EXAMPLE 8

The surgical instrument of Example 7, wherein the first zone is located proximally relative to the second zone.

EXAMPLE 9

The surgical instrument of Example 7, wherein the first zone is located prior to the second zone.

EXAMPLE 10

The surgical instrument of Examples 7, 8 or 9, wherein a length of the first zone corresponds to a thickness of a tissue grasped at the end effector.

EXAMPLE 11

The surgical instrument of Example 10, wherein the surgical instrument comprises a sensor configured to detect a gap between jaw members of the end effector, the gap corresponding to the thickness of the tissue.

EXAMPLE 12

The surgical instrument of Examples 10 or 11 wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue.

EXAMPLE 13

A surgical instrument comprising a motor that includes a control circuit coupled thereto that is configured to detect whether an end effector that is connectable to the surgical instrument is in a closed position. In at least one example, the end effector is configured to receive a cartridge that supports a plurality of staples. The control circuit is further configured to detect a position of a clamping member that is drivable by the motor between a first position, a second position, and a third position. The clamping member is configured to transition the end effector to the closed position as the clamping member moves from the first position to the second position and deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position. The control circuit is further configured to cause the motor to drive the clamping member at a variable rate corresponding to a location of the clamping member between the second position and the third position. In at least one example, the variable rate is slower nearer to the second position.

EXAMPLE 14

The surgical instrument of Example 13, wherein the control circuit is configured to cause the motor to drive the clamping member at a slower rate for a period of time corresponding to a thickness of a tissue grasped at the end effector.

EXAMPLE 15

The surgical instrument of Examples 13 or 14, wherein the surgical instrument comprises a sensor configured to detect a gap between jaw members of the end effector, the gap corresponding to the thickness of the tissue.

EXAMPLE 16

The surgical instrument of Examples 13, 14 or 15, wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue.

Many of the surgical instrument systems described herein are motivated by an electric motor; however, the surgical instrument systems described herein can be motivated in any suitable manner. In various instances, the surgical instrument systems described herein can be motivated by a manually-operated trigger, for example. In certain instances, the motors disclosed herein may comprise a portion or portions of a robotically controlled system. Moreover, any of the end effectors and/or tool assemblies disclosed herein can be utilized with a robotic surgical instrument system. U.S. patent application Ser. No. 13/118,241, entitled SURGICAL STAPLING INSTRUMENTS WITH ROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, now U.S. Pat. No. 9,072,535, for example, discloses several examples of a robotic surgical instrument system in greater detail.

The surgical instrument systems described herein have been described in connection with the deployment and deformation of staples; however, the embodiments described herein are not so limited. Various embodiments are envisioned which deploy fasteners other than staples, such as clamps or tacks, for example. Moreover, various embodiments are envisioned which utilize any suitable means for sealing tissue. For instance, an end effector in accordance with various embodiments can comprise electrodes configured to heat and seal the tissue. Also, for instance, an end effector in accordance with certain embodiments can apply vibrational energy to seal the tissue.

Although various devices have been described herein in connection with certain embodiments, modifications and variations to those embodiments may be implemented. Particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment may be combined in whole or in part, with the features, structures or characteristics of one ore more other embodiments without limitation. Also, where materials are disclosed for certain components, other materials may be used. Furthermore, according to various embodiments, a single component may be replaced by multiple components, and multiple components may be replaced by a single component, to perform a given function or functions. The foregoing description and following claims are intended to cover all such modification and variations.

The devices disclosed herein can be designed to be disposed of after a single use, or they can be designed to be used multiple times. In either case, however, a device can be reconditioned for reuse after at least one use. Reconditioning can include any combination of the steps including, but not limited to, the disassembly of the device, followed by cleaning or replacement of particular pieces of the device, and subsequent reassembly of the device. In particular, a reconditioning facility and/or surgical team can disassemble a device and, after cleaning and/or replacing particular parts of the device, the device can be reassembled for subsequent use. Those skilled in the art will appreciate that reconditioning of a device can utilize a variety of techniques for disassembly, cleaning/replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

The devices disclosed herein may be processed before surgery. First, a new or used instrument may be obtained and, when necessary, cleaned. The instrument may then be sterilized. In one sterilization technique, the instrument is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and instrument may then be placed in a field of radiation that can penetrate the container, such as gamma radiation, x-rays, and/or high-energy electrons. The radiation may kill bacteria on the instrument and in the container. The sterilized instrument may then be stored in the sterile container. The sealed container may keep the instrument sterile until it is opened in a medical facility. A device may also be sterilized using any other technique known in the art, including but not limited to beta radiation, gamma radiation, ethylene oxide, plasma peroxide, and/or steam.

While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of the disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. 

The invention claimed is:
 1. A surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position and a second position, wherein the clamping member is coupled to a drive assembly of the end effector wherein axial translation of the drive assembly causes the clamping member to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge after the end effector is in the closed position as the clamping member moves to the second position; wherein the control circuit is further configured to: cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position; and cause the motor to drive the clamping member at a second rate in a second zone between the first position and the second position; wherein the first rate is less than the second rate.
 2. The surgical instrument of claim 1, wherein the first zone is located proximally relative to the second zone.
 3. The surgical instrument of claim 1, wherein the first zone is located prior to the second zone.
 4. The surgical instrument of claim 1, wherein a length of time or distance that the clamping member is advanced at the first rate in the first zone corresponds to a thickness of a tissue grasped at the end effector.
 5. The surgical instrument of claim 4, wherein the surgical instrument comprises a sensor configured to detect a gap between jaw members of the end effector, the gap corresponding to the thickness of the tissue.
 6. The surgical instrument of claim 4, wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue.
 7. A surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position, a second position, and a third position, wherein the clamping member is coupled to a drive assembly wherein axial translation of the drive assembly causes the clamping member to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position; wherein the control circuit is further configured to: cause the motor to drive the clamping member at a first rate in a first zone between the first position and the second position; and cause the motor to drive the clamping member at a second rate in a second zone between the second position and the third position; wherein the first rate is less than the second rate.
 8. The surgical instrument of claim 7, wherein the first zone is located proximally relative to the second zone.
 9. The surgical instrument of claim 7, wherein the first zone is located prior to the second zone.
 10. The surgical instrument of claim 7, wherein a length of time or distance that the clamping member is advanced at the first rate in the first zone corresponds to a thickness of a tissue grasped at the end effector.
 11. The surgical instrument of claim 10, wherein the surgical instrument comprises a sensor configured to detect a gap between jaw members of the end effector, the gap corresponding to the thickness of the tissue.
 12. The surgical instrument of claim 10, wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue.
 13. A surgical instrument comprising: a motor; and a control circuit coupled to the motor, the control circuit configured to: detect whether an end effector connectable to the surgical instrument is in a closed position, the end effector configured to receive a cartridge supporting a plurality of staples; and detect a position of a clamping member drivable by the motor between a first position, a second position, and a third position, wherein the clamping member is coupled to a drive assembly wherein axial translation of the drive assembly causes the clamping member to: transition the end effector to the closed position as the clamping member moves from the first position to the second position; and deploy the plurality of staples from the cartridge as the clamping member moves from the second position to the third position; wherein the control circuit is further configured to cause the motor to drive the clamping member at a variable rate corresponding to a location of the clamping member between the second position and the third position, the variable rate being slower nearer to the second position.
 14. The surgical instrument of claim 13, wherein the control circuit is configured to cause the motor to drive the clamping member at a slower rate for a period of time corresponding to a thickness of a tissue grasped at the end effector.
 15. The surgical instrument of claim 14, wherein the surgical instrument comprises a sensor configured to detect a gap between jaw members of the end effector, the gap corresponding to the thickness of the tissue.
 16. The surgical instrument of claim 14, wherein the control circuit is configured to detect a current of the motor as the end effector transitions to the closed position, the current of the motor corresponding to the thickness of the tissue. 